Design, Fabrication and Testing of a Versatile Outfitting Attachment System Kit for Naval Sandwich Panels

KaZaK Composites and UMass-Lowell will extend a successful Phase I analytical and experimental investigation of outfitting attachment hardware optimized for composite sandwich panels used as shipboard structures. The KCI/UML team will work with Bath IronWorks to ensure that attachment system solutions developed during the program are compatible with demanding and diverse needs associated with Naval fleet service. Phase I demonstrated several attachment configurations meeting static load requirements.Phase II will focus on design refinement, culminating in shock testing of attachments on full scale composite panel structures. Work will fall into the following general categories: 1) Extension of Phase I classical and finite element analysis of candidateinserts, including evaluation of effects of likely installation errors such as poor back surface attachment or misalignment, on strength of the installed attachment, 2) Fabrication of full-scale sandwich test panels made by VARTM and pultrusion processes,3) Testing candidate systems statically for in-plane and out-of-plane failure loads, 4) Subjecting final attachment hardware to shock testing, followed by measurement of strength after shock, and 5) Definition of a generally-applicable, pre-kitted panelinsert system and User's Manual for use by shipbuilders and maintenance personnel, and 6) Delivery of prototype ready-to-use kits to the Navy. KaZaK Composites is actively involved in the development of numerous products that make use of our uniquecapability to pultrude sandwich panel structures up to10 feet wide, 2 feet thick and of unlimited length. Current KCI programs include use of these pultruded sandwich panels in large deployable military buildings, Navy pier structures (with skins as thickas 3 inches) and various transportation systems. We plan to use our own developmental hardware as the first