Design, Fabrication and Testing of Low Cost Composite and Metal/Composite Hybrid Lattice Fins

KaZaK Composites and our program partner, Raytheon Missile Systems, propose to investigate the design, low cost manufacture and testing of several material and process alternatives for making a less costly replacement for a current baseline EDM-fabricatedstainless steel lattice fin. KCI's current leading candidate, an all-graphite/epoxy fin, when combined with our expected low cost production process, should result in a minimum 90% cost reduction compared to the $2,000 baseline fin price. In addition tothe all-composite design, we will also consider hybrid systems that combine a composite lattice with a metal base, and improved systems for making all-metal fins. Because the stated application is subsonic rather than supersonic, high temperature issuesthat may have precluded low cost metal production technology might be applied to reduce the cost of the low speed metal designs.During Phase I KCI will fabricate several prototype lattice fin prototypes and subject them to static load testing. We also will perform full scale dynamic pressure deployment tests using a water tunnel during Phase I. Working with Raytheon, we willproject the synergistic weight and cost reduction that a lighter lattice fin might generate in a resized missile control actuation system.RCS reduction considerations are driving aircraft armament toward internal stores requirements. This will necessitate the development of smaller weapons without a reduction in capability. The lattice fin is a technology that helps this evolution by bothcreating a tighter package size, and by reducing the requirements on the control actuation system, allowing that to become smaller as well. Cost has been one of the impediments to the general acceptance of lattice fin technology in the US. Successfulcompletion of the proposed Phase I and II work should create a cost effective solution for manufacturing the lattice fin structure. Once proven, it is expected that the market for weapons making use of this technology will grow quickly as new, smaller,smarter, more capable weapons are purchased to supply the more stealthy aircraft, designed for internal weapons carriage that will be entering the fleet.