Pultrusion-Based Fabrication of Revolutionary Phenolic Foam Replacement for Balsa in Navy Ship Structures

KaZaK Composites proposes development of a revolutionary fire resistant structural core material that will ultimately become a replacement for balsa in Navy sandwich panel construction. Balsa is currently the baseline material for structures like the DD(X) composite deckhouse. However, this baseline material has a number of shortcomings including inconsistent material properties (because it is a natural material), moisture absorption and associated degradation, and absorption of a considerable weight of resin during the VARTM manufacturing process. KaZaK's phenolic-based alternative will have far more consistent mechanical properties, and has been formulated to improve fire and impact resistance. KaZaK will also demonstrate an innovative manufacturing process for making sandwich panels of the type used by DD(X) that, once perfected, will greatly reduce the cost and simultaneously improve the performance of composite sandwich marine structures. In Phase I KaZaK will fabricate a large number of core material formulation alternatives and subject them to mechanical and fire tests to evaluate their relative performance. In addition sandwich panels will be constructed using a unique processing approach, tested in bending and impact, and results compared to balsa. Results will be reviewed by NGSS and other shipbuilders as part of KaZaK's regular meetings with our existing customer base.