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Final Report Contract N00167-99-C-0044 SBIR N99-97 Contract Carderock Division Naval Surface Warfare Ctr. Attn: Code 6553, Roger Crane 9500 MacArthur Blvd. West Bethesda, MD 20817-5700 1.0. Identification and Significance of the Opportunity The primary limitation for the wider use of composites is the cost. (Other aspects such as fire resistance and enhanced properties such as higher service temperatures can also be of concern.) The major cost element of composites is the actual fabrication step which accountsforover60%ofthecost. Thisisfollowedbythecostofmaterialwasteandthen the actual cost of materials used in the part. Therefore, the focus of this SBIR Topic N99- 097 is directed to finding and developing new manufacturing concepts which eliminate the under the bag distribution media, material waste, and reduce actual manufacturing costs. 1.1. Background and Identification of the Opportunity The manufacturing area for composites which is receiving the significant focus for the fabrication for large size structures is VARTM (vacuum assisted resin transfer molding). This is because VARTM represents a fast way of impregnating a fibrous fabric reinforcement in final part form, eliminates the use of the expensive autoclave (process time, labor, capital cost, and part size restraints), and expensive and difficult to store prepregs. There are several varieties of VARTM processes being used including the most publicized process, SCRIMP. Sunrez has recently completed two different process demonstration projects for the NAVY (Carderock) in their Advanced Composite Hull Fabrication Process Evaluation Program. The Sunrez UV-VARTM processes which utilized light curing resins was substantially lower cost with respect to total manufacturing cost than any other VARTM process evaluated or being used commercially. The advantages of both the light cured UV-VARTM and UV-Prepreg processes include less material waste, faster processing time, far less in-mold time, minimal or no styrene emissions, longer working time, substantially less clean up, and a more robust process than any other process evaluated. These light cured resin processes are well suited for fiberglass withvinylesterresins,polyesterresinsandotherphotocurableresins. Inaddition,these processes are fast curing and yet permit very long working times for filling the one-part light curable resin into the fibrous reinforcement. These low cost processes, the Sunrez UV- VARTM Process and the Sunrez UV-Prepreg process, do not work with reinforcements and structuresopaquetoUVAlightwhichisnecessaryforcuringtheseresins. Inaddition,many -1-PDF Image | Affordable NDM Vacuum Assisted Resin Transfer Molding
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