Design, Fabrication and Testing of a Versatile Outfitting Attachment System Kit for Naval Sandwich Panels

KaZaK Composites and the University of Massachusetts-Lowell will conduct an analytical and experimental investigation of technology alternatives for mounting hardware to composite sandwich panels used in shipboard structures. The KCI/UML team will workwith Bath Iron Works to ensure that attachment system solutions developed during the program are compatible with demanding and diverse needs associated with Naval fleet service. Phase I work will fall into five general categories: 1) Evaluation ofavailable fastener systems and suppliers (the currently favored approach for meeting Navy RFP specifications is a full depth potted insert system), 2) Classical and finite element analysis of various combinations of insert and panel, including anevaluation of effects of likely installation errors, such as poor back surface attachment or misalignment, on strength of the installed attachment, 3) Fabrication of sandwich test panels made with various cores, faced with glass or carbon skins, includingpurposely less-than-perfect insert installations, as well as different manufacturing processes including a VARTM-like process and pultrusion, 4) Testing candidate systems statically for in-plane and out-of-plane failure loads, plus strength after shockloading and/or fatigue cycling, and 5) Definition of a generally-applicable, pre-kitted panel insert system and User's Manual for use by shipbuilders and maintenance personnel.KaZaK Composites is actively involved in the development of numerous productsthat make use of our unique capability to pultrude sandwich panel structures up to 10 feet wide, 2 feet thick and of unlimited length. Current KCI programs include use of these pultruded sandwich panels in large deployable military buildings, Navy pierstructures (with skins as thick as 3 inches) and various transportation systems. We plan to use our own developmental hardware as the first