Co-Infusion of Multiple Resins for Enhanced Fire Resistance

Composite structures are highly desirable for future Navy surface ships due primarily to their high strength to weight ratio, corrosion resistance and radar signature reduction potential. The recent National Research Council (NRC) study on technology needs for the 21st century (1) specifically cites the use of composite materials for signature reduction as one of the three primary development recommendations for Navy platforms. However, flammability/smoke/toxicity (FST) concerns have long hindered the implementation of composite structures into Navy warships and US commercial vessels. In the proposed Phase I program, Foster-Miller will evaluate and develop several options for co-infusion of two distinct resin systems into a single composite structure. A central performance goal of each of these options will be to provide the necessary fire barrier as an integral part of a composite structure while also yielding suitable structural performance and low manufacturing costs. Foster-Miller has previously demonstrated a unique intumescent composite matrix resin that provides improved fire barrier performance over standard phenolic resin systems. This resin system will be evaluated in the proposed program as one of the co-infusion resin systems. The proposed program will evaluate these options against the necessary performance specifications identified by Foster Miller and our team members Bath Iron Works and Techmatics. Following initial evaluation, a minimum of two co-infusion approaches will be carried through testing and evaluation against criteria including fire and structural performance, processability and cost. The program will culminate in the fabrication and testing of a sub-component to demonstrate the performance of the best approach during the optional phase of the program.