Braiding and Resin-Transfer-Molding for Low-Cost, Damage-Resistant Aircraft Primary Structures

This project will produce innovative improvements over current practices in the fabrication of composite primary structures using braiding, resin transfer molding, and low cost materials. This effort addresses needs for cost effective manufacturing, improved damage resistance, and reduced noise transmission. The overall objective of Phase I is to select a material set for eventual fabrication into stiffener components. The specific objectives are to determine the effects of braid interlacing, fiber combinations, and resins types on the in-plane mechanical, acoustic, and impact properties of the final composite. In a two task effort, thin guage flat panels made from hybrid braids of carbon, glass and Kevlar fibers and three types of epoxy resin will be tested and the data compared. In a final task, a demonstration component will be fabricated and tested. We expect to find that hybrid braids and low cost resins can provide cost effective improvements to composite acoustic and impact properties. We expect that Phase I results will lead directly to Phase II hardware fabrication and testing. Teamed with Beech Aircraft, we expect to eventually test full scale wings and fuselage sections, receive FAA certification and commercialize a new generation aircraft per NASA's long term goals.