Multifunctional Nanoforest Property Improvements for High-Temperature Polymer and Ceramic Matrix Composites

Goodman Technologies (GT) demonstrated 2 aligned carbon nanotube (ACNT) approaches (Nanoforest I, aka VACNT, and patent pending 3-Dimensional Nanoforest III, aka ONT) which provided double-digit percentage improvements in the fracture toughness of commercially available AFR-PE-4 and RM-1100 polyimide systems (Teijin/Renegade Materials), and in Carbon/Epoxy. GT’s breakthrough ACNT enhancements of PMCs and CMCs will provide the requisite improvements in laminate orthogonal properties at the high-temperature required for engine compressor and nozzle structures: the GE-F414 engines used in  PMA-265 (the Navy’s F/A-18 and EA-18G Program Office) which acquires, delivers and sustains the F/A-18C/D Hornet, the F/A-18E/F Super Hornet, and the EA-18G Growler aircraft, the Joint Program Office F-35C for the Navy’s F-35C Lightning II Pratt & Whitney F135 engine, and the as yet to be definitized Next-Generation Air Dominance (NGAD). The F110-GE-129 engine is used by the Air Force and foreign militaries for the Lockheed Martin F-16C/D Block aircraft, as well as the Boeing F-15QA Advanced Eagle.  For Hypersonics key stakeholders are ONR Division 351 and Conventional Prompt Strike (CPS) at Strategic Systems Programs (SSP) with the primary customers being OPNA, COMUSSSTRATCOM, PEO (SUB), and PEO (Ships). The U.S. Army is a partner with the Navy for the Common Hypersonic Glide Body (C-HGB) VACNT and ONT presents an extraordinary opportunity for the F-35 Lightning II Program (PEO -F-35) and the three DoD Components which use this single-seat, single-engine, all-weather stealth multirole combat aircraft – F-35A for the Air Force, F-35B for the Marine Corps, and F-35C for the Navy. The General Accounting Office (GAO) F-35 Reports 20-234T and 20-339 have stated “DoD faces challenges in sustaining a growing fleet”, and “actions are needed to address manufacturing and modernization risks. The reports show that the summation of scrap, rework, and repair hours for all 435 of the F-35 variants increased in 2018-2019, >26,000 hours total in 2019. As of January 2021, there are over 610 aircraft built. Delamination failures are pervasive, as are achieving dimensional tolerances, a major problem for many aircraft programs. GT's Nanoforest composites increase toughness and strength, improve EMI/EMP shielding, reduce weight and radar cross section, and improve dimensional tolerances (tighter radii), and flame retardance. Improvements of 30-60% in fracture toughness can equate to proportionate reductions in scrap, rework and repair hours. Parametric analysis showed that when the F-35 fleet grows to >2400 air that nanoforest could save 33,000-73,625 hour/year Savings for Scrap, Rework, Repair. Using an average cost of $300/hour (no inflation) for Scrap, Rework, Repair, Multiply by 4-5 Decades Service, and the Savings range from $397M- $1107M, that gives Leverage of 397-1107X for a $1M SBIR investment.