Truss Reinforced Foam Cores for Replacement of Aluminum Honeycomb Structures

"Sandwich core structures represent a lightweight and structurally efficient approach for composite airframe fabrication. However, the use of sandwich core structures has also presented many challenges, particularly for Navy aircraft that tend to seeextensive exposure to salt spray and high humidity environments. In these environments, any defect or damage to the sandwich facesheets allows moisture intrusion into the cells of the honeycomb. Once this process has begun, the result is almost inevitable- corrosion of the metallic components and delamination of the facesheets from the core.Aztex has developed a technology that utilizes a lightweight, closed cell foam as a base. The foam is then reinforced with very small diameter pultruded rods. This technology provides a means to utilize a closed cell foam core with relatively poormechanical properties and by the addition of Z-FiberT rods, create a high strength, damage tolerant core structure with the potential for strengths comparable to aluminum honeycomb.In this program, Aztex proposes to utilize our K-CorT product as a basis to develop a replacement core material for aircraft control surfaces, focusing on the F-14. This technology would be applicable to other existing or future aircraft applications.Aztex has developed a technology that utilizes a lightweight, closed cell foam as a base. The foam is then reinforced with very small diameter pultruded rods. This technology provides a