Improved Lifetime Performance of Nonmetallic Honeycomb Cored and Modified Aluminum Cored Honeycomb Structures

The objective of the proposed Phase II program is to develop, refine, prove, and qualify methods, materials, and processes for the fabrication of replacement honeycomb-core bonded metal aircraft structures that have at least a 5-year lifetime under at-seaconditions. The results of the Phase I effort have shown that new honeycomb-core materials and adhesives are commercially available that have significantly better corrosion resistance than the original materials. The Phase II program will build on andexpand those results to yield specifications and production capability for improved lifetime honeycomb-core structures for legacy naval aircraft such as the F-14. Upon completion of the Phase II program, Aurora Flight Sciences Corp. will be positioned forfull production of fully qualified honeycomb-core replacement parts for military and commercial aircraft. 1.New honeycomb-core materials and adhesives will be identified and qualified that can be used to construct honeycomb-core sandwich structures thathave an extended typical service life of 60 months or greater under at sea conditions (compared to 30 months for the current structures). These materials will be fully qualified through rigorous coupon-level testing and full component fabrication andtesting. Final fabrication procedures and materials will be fully documented under Aurora's ISO 9002 certification.2. Production methods and capabilities will be developed that will enable Aurora Flight Sciences to supply improved performance replacement honeycomb-core sandwich structure parts for Naval and commercial aircraft. Production of replacement parts will bepossible even if complete design specifications are not available