Low Cost Composite Manufacturing of Large Scale Hydrodynamic Surfaces

Production Products and the University of Delaware Center for Composite Materials will develop low cost vacuum assisted resin transfer molding (VARTM) composite fabrication techniques and design for the manufacture of dimensionally criticalhydrodynamically smooth lifting surfaces for Naval vessels. This will lead to significant reduction in the cost of ownership of composite rudders which are inherently lighter, more durable, corrosion resistant, better acoustically and resistant tocavitation. In Phase I we will demonstrate low cost VARTM processes for manufacture of a structure with two hydrodynamically smooth, complex curved surfaces. These concepts will focus on processing methods, core materials, preform methods, low costtooling, surface coatings and control surface rigidity. We will manufacture and test representative articles using this VARTM technique. In Phase II we will manufacture a large scale composite lifting surface using the developed low cost VARTM processand demonstrate that the structure has been designed to maintain an optimum angle of attack over a large pressure range. In Phase III we will manufacture and qualify a full scale composite lifting surface optimized for low cost and stiffness. Thisstructure will be installed on a surface ship such as a DDG-51 flight 2-A class ship for ship evaluation.The low cost VARTM technology developed on this program will have direct applicability to Navy surface ships and submarines and will result inimmediate use for the rudder of DDG-51 flight 2-A class ships. The technology could be utilized to manufacture similar lifting surfaces for large ocean going vessels such as cargo and cruise ships as well as Coast Guard vessels.