Design, Fabrication and Testing of Low Cost Composite and Metal/Composite Hybrid Lattice Fins

"KaZaK Composites, our Phase II subcontractor Dynetics, along with Boeing and Raytheon, propose to investigate the design, low cost manufacturing and testing of inexpensive alternatives to EDM-fabricated baseline stainless steel lattice fins currentlycosting the Air Force more than $2,000. In Phase I, alternative manufacturing methods for making composite, stainless steel and hybrid material/composite fins at costs of between $100 and $200 were demonstrated. KCI's leading candidate for subsonic finapplications is an all-graphite/epoxy design. Low cost stainless steel and hybrid material fin designs that combine a composite lattice with a metal attachment fitting were also developed and tested in Phase I.Phase II will extend Phase I developments by fabricating improved, production-quality tooling systems that permit better manufacturing precision than was possible within the Phase I budget. Considerable Phase II effort will be devoted to developing methodsfor cost-effectively shaping the leading edges of grid structures. Several iterative rounds of fin design, fabrication and performance verification via static and dynamic wind tunnel testing are planned. The objective of Phase II will be the demonstrationof one or more fully verified, low cost lattice fins that can be used in current or future systems defined by our aerospace partners."