Pultrusion Processes for Producing Composite Structures

The widespread use of advanced composites has been severely impeded by the lack of an economical fabrication technology. The advantages of the Pultrusion Process in this regard have long been recognized by the composite community, and part shaping of pultuded sections has been identified as a promising means of producing a range of structural components in recent cost modeling initiatives (NASA/ACT). However, the major drawback of the process is the restriction to linear cross section (prismatic) components. Practicable reshaping techniques and methods of imparting complex curvatures are now being developed. This work combines controlled thermal distortion with recently developed Selective Interval Pulshaping Technology to provide a processing strategy to produce circumferencial and longitudinal stiffening elements of aircraft fuselage and other aerospace structures, with process economics exceeding any existing by at least a factor of two. Proprietary techniques will be used to produce elastomeric matrix sections to provide structures with enhanced vibration damping. Full scale pultrusion trials will be carried out in conjunction with analytical and numerical modeling activities to establish the feasibility of developing fabrication technologies applicable to both BMDO needs and commercial opportunity.