Z-Fiber Reinforced RTM Composties

Resin transfer molding (RTM) is a low-cost composites fabrication method used in many commercial products and secondary aircraft structures such as doors. This project investigates a low-cost concept for fabricating higher strength RTM composites enabling their use in primary aircraft structures. The approach uses discrete fiber reinforcements positioned transverse to fabric or through a stiffener-skin interface. Novel fabrication methodology is proposed that achieves 3-D architecture without weaving or stitching. The methodology is fundamentally low-cost and is scaleable to large preform articles and roll-to-roll products. Phase I will develop the z-fiber implantation process for RTM preforms and fabricate a matrix of planar RTM composite parts for mechanical testing in-house. Selected articles will be tested by a major airframer possessing a database of materials properties for comparison. The results of testing and analysis will be used to determine the achievable strengths vs fiber configuration. The suitability of the concept for primary aircraft structures will be assessed. Other potential benefits of transverse fibers to functions such as thermal management or lightning strike protection will be assessed. Phase II would further develop the methodology and scale up to the fabrication of prototype components such as a skin with integral stiffeners. Component design and testing would be performed in collaboration with an airframer. Anticipated Benefits: Low-cost high strength RTM composites would have broad structural application for air and land transportation.