Design Optimization of High-Pressure Resin Transfer Molding Process for Aircraft Structural Application
Abstract
Over the past decade, the U.S. Navy has embraced the use of composites into their ships, composite deckhouses, and other superstructures. Composites have significant advantages over traditional steel structures with respect to maintenance and repair costs because of their corrosion resistance, high specific strength or strength to weight ratio, high impact resistance, and their ability to be tailored to increase design flexibility and performance. Advanced composite material coupled with advanced manufacturing techniques such as resin transfer molding (RTM) or vacuum-assisted resin transfer molding (VARTM) can significantly reduce the part count and therefore, productioncost of the airplane. The early applications of braided composites were limited to secondary structures. However, the use of braided RTM inboard and outboard flaps of Raytheon Premier I business jet has shown a 50 percent reduction in weight and 35 percent reduction in labor cost compared to metal counterpart. Significant reduction in part count and high dimensional tolerances achieved through creative tool design also contributed this successful application. In order to produce high quality, repeatable parts with minimum or no defects, process simulations must be employed at early stages of manufacturing process optimization and tool design. This also aid the certification process, especially for aircraft applications, that typically come with the addedexpense of extensive certification requirements, which necessitate extensive testing andunderstanding of mechanics of materials. In addition to traditional RTM and VARTM processes, high pressure RTM (HP-RTM) process that is utilized by automotive for high-rate production of lightweight structures will also be considered. In order to aid aircraft structural design and manufacturing optimization, a detailed investigation will be carried out for validating analytical techniques for high-pressure infusion process optimization of dry fiber preforms prepared using automated fiber placement. In addition to developing optimal injection strategies, analytical tools can also be for designing tools to avoid costly and time-consuming trial-and-error processes.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Jun 09, 2021
- Source ID
- N000142112528
Entities
People
- Waruna Seneviratne
Organizations
- Office of Naval Research
- United States Navy
- Wichita State University