Ultrasonically Assisted Z-Fiber (UAZ) Technology for Widespread Airframe Structure Application

Limitations of composites include low interlaminar properties, damage susceptibility, and lack of efficient joining methods. Research has been conducted to develop through thickness reinforcement technologies to offset these limitations. Foster-Miller's Z-Fiber process has demonstrated 30 fold increases in fracture toughness with little degradation to in-plane properties. This baseline Z-Fiber process has promise to limit airfoil structure FOD Damage and as a joining method for co-cured stiffened skin structures. Boeing and FM IRADs and Wright Lab initiated JTCG seed funding has demonstrated feasibility of an advance version of Z-Fiber technology entitled Ultrasonically Assisted Z-Fiber (UAZ). In this process ultrasonic technology replaces autoclave heat and pressure requirements. The UAZ process makes additional applications for Z-Fiber feasible along with reinforcement of cured thermoset and thermoplastic structures. Successful development of this technology offers cost reduction, repair options, joining of cured structures, and application to thermoplastics and complex contours. Boeing and FM plan to support UAZ with CY95 IRAD. Additional SBIR funding would maximize the potential to bring this technology to the shop floor. In Phase I FM and Boeing would investigate technology potential, mechanical performance, system concepts and application areas. The program would conclude with demonstration component fabrication.