Innovative Low Cost, Lightweight Sandwich Cores

The availability of lightweight, low cost core materials for sandwich construction could dramatically improve Air Force composite structures across-the-board. In this program, Foster-Miller will demonstrate the huge advances that are possible by applying advanced materials technology, including blends of high performance polymers such as LaRC-TPI 1500/Xydar, to the production of new forms of foam and honeycomb core materials for aircraft applications. The use of these advanced polymeric materials in cores would make available thermally stable, melt-processible sandwich structures which are strong and stiff, lightweight, insensitive to moisture, and dimensionally-stable. Using our extensive processing experience with advanced polymers and their blends, and making use of the expertise of teaming partners Hexcel and Vought, Foster-Miller will examine the feasibility and practicality of honeycomb cores made from these materials. Furthermore, we will examine the ability to fabricate foam core materials which have 2 to 3 times the specific stiffness of the best aerospace foam material currently available. The work plan provides a balanced and coordinated approach including analysis, processing experiments, production of actual core material, and determination of core material properties. Also included is an economic analysis of the potential cost of the advanced core material in production.