Now MIT engineers have developed a method to produce aerospace-grade composites without the enormous ovens and pressure vessels. The technique may help to speed up the manufacturing of aeroplanes and other large, high-performance composite structures, such as blades for wind turbines.

The researchers detail their new method in a paper published in the journal Advanced Materials Interfaces.

If you’re making a primary structure like a fuselage or wing, you need to build a pressure vessel, or autoclave, the size of a two- or three-story building, which itself requires time and money to pressurize. These things are massive pieces of infrastructure. Now we can make primary structure materials without autoclave pressure, so we can get rid of all that infrastructure. Brian Wardle, professor of aeronautics and astronautics at MIT

Wardle’s co-authors on the paper are lead author and MIT postdoc Jeonyoon Lee, and Seth Kessler of Metis Design Corporation, an aerospace structural health monitoring company based in Boston.

Out of the oven, into a blanket

In 2015, Lee led the team, along with another member of Wardle’s lab, in creating a method to make aerospace-grade composites without requiring an oven to fuse the materials together. Instead of placing layers of material inside an oven to cure, the researchers essentially wrapped them in an ultrathin film of carbon nanotubes (CNTs). When they applied an electric current to the film, the CNTs, like a nanoscale electric blanket, quickly generated heat, causing the materials within to cure and fuse together.

With this out-of-oven, or OoO, technique, the team was able to produce composites as strong as the materials made in conventional aeroplane manufacturing ovens, using only 1 per cent of the energy.

The researchers next looked for ways to make high-performance composites without the use of large, high-pressure autoclaves — building-sized vessels that generate high enough pressures to press materials together, squeezing out any voids, or air pockets, at their interface.

Researchers including Wardle’s group have explored “out-of-autoclave,” or OoA, techniques to manufacture composites without using the huge machines. But most of these techniques have produced composites where nearly 1 per cent of the material contains voids, which can compromise a material’s strength and lifetime. In comparison, aerospace-grade composites made in autoclaves are of such high quality that any voids they contain are negligible and not easily measured.

Straw pressure

Part of Wardle’s work focuses on developing nanoporous networks — ultrathin films made from aligned, microscopic material such as carbon nanotubes, that can be engineered with exceptional properties, including colour, strength, and electrical capacity. The researchers wondered whether these nanoporous films could be used in place of giant autoclaves to squeeze out voids between two material layers, as unlikely as that may seem.

A thin film of carbon nanotubes is somewhat like a dense forest of trees, and the spaces between the trees can function like thin nanoscale tubes or capillaries. A capillary such as a straw can generate pressure based on its geometry and its surface energy, or the material’s ability to attract liquids or other materials.

The researchers tested their idea in the lab by growing films of vertically aligned carbon nanotubes using a technique they previously developed, then laying the films between layers of materials that are typically used in the autoclave-based manufacturing of primary aircraft structures. They wrapped the layers in a second film of carbon nanotubes, which they applied an electric current to heat it up. They observed that as the materials heated and softened in response, they were pulled into the capillaries of the intermediate CNT film.

The resulting composite lacked voids, similar to aerospace-grade composites that are produced in an autoclave. The researchers subjected the composites to strength tests, attempting to push the layers apart, the idea being that voids, if present, would allow the layers to separate more easily.

The team will next look for ways to scale up the pressure-generating CNT film. In their experiments, they worked with samples measuring several centimetres wide — large enough to demonstrate that nanoporous networks can pressurize materials and prevent voids from forming. To make this process viable for manufacturing entire wings and fuselages, researchers will have to find ways to manufacture CNT and other nanoporous films at a much larger scale.

He plans also to explore different formulations of nanoporous films, engineering capillaries of varying surface energies and geometries, to be able to pressurize and bond other high-performance materials.

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The acquisition which is subject to customary conditions, including securing regulatory approvals is expected to close by late fourth quarter 2015 or early first quarter 2016. The transaction will have no impact on the company’s previously stated commitments to return cash to shareholders through dividends and to reduce outstanding share count to below 300 million shares by the end of 2017.

Lockheed Martin and United Technologies Corporation have agreed to make a joint election under Section 338(h)(10) of the Internal Revenue Code, which treats the transaction as an asset purchase for tax purposes. The election generates a tax benefit with an estimated present value of $1.9 billion for Lockheed Martin and its shareholders.

Lockheed plans to align Sikorsky under its Mission Systems and Training (MST) business segment. MST and Stratford, Conn., based Sikorsky currently partner on a number of critical programs, including the VH–92 Presidential Helicopter, Combat Rescue Helicopter and the Naval MH–60 Helicopter.

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The space agency has chosen the National Institute of Aerospace (NIA) in Hampton, Virginia, to manage administration of the Advanced Composites Consortium, which is working to improve composite materials research and certification.

Included in this consortium is NASA’s Advanced Composites Project, managed from the agency’s Langley Research Centre in Hampton; the Federal Aviation Administration (FAA); General Electric Aviation, Cincinnati; Lockheed Martin Aeronautics Company, Palmdale, California; Boeing Research & Technology, St. Louis; a team from United Technologies Corporation led by subsidiary Pratt & Whitney in Hartford, Connecticut; and the NIA.

Jaiwon Shin, associate administrator for NASA’s Aeronautics Research Mission Directorate in Washington said;

NASA is committed to transforming aviation through cutting edge research and development. This partnership will help bring better composite materials into use more quickly, and help maintain American leadership in aviation manufacturing.

The NIA will deal with communications from within the consortium and help manage the programmatic and financial aspects of members’ research projects. The NIA also will serve as a “tier two” member with a representative on the consortium’s technical oversight committee.

NASA formed the consortium in support of the Advanced Composites Project, which is part of the Advanced Air Vehicles Program in the agency’s Aeronautics Research Mission Directorate. The project’s goal is to reduce product development and certification timelines by 30% for composites infused into aeronautics applications.

A panel of NASA, FAA and Air Force Research Laboratory experts reviewed 20 submissions and chose the members based on their technical expertise, willingness and ability to share in costs, certification experience with government agencies, and their focused technology areas and partnership histories.

Representatives from each organisation in the consortium participated in technology goal planning discussions, assembled cooperative research teams, and developed draft plans for projects in three areas: prediction of life and strength of composite structures, rapid inspection of composites and manufacturing process and simulation.

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Earlier in the year Lockheed began fabrication of the Dream Chaser orbital spacecraft structure at NASA’s Michoud facility in New Orleans. As each structural component completes the fabrication and inspection process at MAF, it is transported to Lockheed Martin’s Aeronautics facility in Fort Worth, Texas for integration into the airframe and co-bonded assembly.

The Fort Worth facility manufactures and assembles the world’s top fighter aircraft, here the company applies the latest advanced 3D preform technology on the Dream Chaser for joint assemble, reducing the overall part and tooling count while improving assembly and integration time. Through these processes, SNC and Lockheed Martin are able to improve the overall durability, weight efficiency and affordability of the spacecraft.

SNC is working with NASA’s Commercial Crew Program under an existing space act agreement to develop a safe, innovative, modern, flexible and highly capable commercial space transportation system for the 21st Century. Once developed, Dream Chaser will provide the only reusable, human-rated lifting-body spacecraft with a commercial runway landing capability, anywhere in the world, and is on the forefront of the commercial human spaceflight industry, offering safe, reliable and cost-effective crew and critical cargo transportation to and from low-Earth orbit.

Upon completion of manufacturing Lockheed Martin will transport the Dream Chaser airframe to SNC’s Louisville, Colorado, facility for final integration and assembly.

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Under the signed Memorandum of Understanding, SABIC and Lockheed Martin will coordinate on the development, industrial validation, testing, scale-up, production and sale of carbon nanostructure materials and carbon nanostructure infused products. Carbon nanostructures can be grown at scale on various substrates and formed into materials with superior structural and conductive properties.

Commenting on the joint venture MoU, Ernesto Occhiello, SABIC Executive Vice President, Technology & Innovation said;

We are happy that Lockheed Martin has shown their intention to share their newly developed technology with SABIC. An innovative partner like Lockheed Martin is indeed valuable to us, and we hope the initiative will be the beginning of a longer term relationship with the company.

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The companies that are in the partnership include Bell Helicopters, GE Aviation, Lockheed Martin, Northrop Grumman, Boeing and United technologies. These companies were selected from 20 proposals submitted by teams from industry and academia in response to a call from the Advanced Composites Project, which is part of NASA’s Aeronautics Research Mission Directorate’s Integrated Systems Research Program.

The project sought proposals to reduce the time for development, verification and regulatory acceptance of new composite materials and structures. A panel of experts from NASA, the Federal Aviation Administration and the U.S. Air Force Research Laboratory reviewed the submissions and assessed them according to specific criteria. The six firms were chosen for their technical expertise, willingness and ability to share in costs, certification experience with government agencies, focused technology areas and partnership histories.

The first task for the new team is to develop articles of collaboration and establish how the alliance will work and how companies may be added in the future.

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Mike Blair, vice president and general manager of the Exelis Aerostructures business said;

Our expertise in fabricating complex, high-performance composite structures provides the highest-quality solutions at the best value for our customer, with our commitment to operational excellence, we will maximise that value, offering the right processes more efficiently to meet our customer’s needs.

Exelis has over 40 years of experience in the design and manufacture of composite structures and assemblies. Composite structures are used increasingly by commercial and military aircraft manufacturers as a proven alternative to metal structures to help decrease an aircraft’s weight and fuel consumption and increase its resilience to environmental conditions and in-flight stress.

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Northrop Grumman have entered into a long-term agreement with the advanced composites manufacturer Terma A/S in Denmark to manufacture component parts for the international F-35 Lightning II program.

The agreement, which has a potential value of more than $97 million upon completion of all follow-on options, was signed on Sept. 20 and further emphasises the company’s commitment to supporting F-35 Lightning II partner countries.

The deal covers production of 34 unique F-35 Lightning II composite components, including door, panel, skin assembly and straps through 2019. The agreement further strengthens the partnership between Northrop Grumman and Terma A/S, which began in 2006. The first purchase order placed in 2007 during the Low Rate Initial Production 1 statement of work solidified the collaborative relationship between Northrop Grumman and Terma A/S, which has manufacturing responsibility for hardware on all three F-35 aircraft variants.

The signing has spurred discussions on how Northrop Grumman and Terma A/S can collaborate on affordability initiatives benefitting both companies and the F-35 program as a whole. The companies will explore technologies, set a path forward to achieve manufacturing efficiencies to meet the necessary quality requirements and work toward establishing Terma A/S as a premier supplier of composite parts.

Michelle Scarpella, vice president of the F-35 program for Northrop Grumman said;

The LTA with Terma A/S further strengthens our relationship with Denmark, an F-35 partner country, under this agreement, we will continue to work collaboratively with Terma, striving for the highest quality and driving efficiencies so we are able to provide the war fighter with the world’s most advanced strike fighter aircraft.

As a principal member of the Lockheed Martin-led F-35 industry team, Northrop Grumman performs a significant share of the work required to develop and produce the aircraft. In addition to producing the F-35 center fuselage, Northrop Grumman designed and produces the aircraft’s radar and other key avionics including electro-optical and communications subsystems; develops mission systems and mission-planning software; leads the team’s development of pilot and maintenance training system courseware; and manages the team’s use, support and maintenance of low-observable technologies. To date, the company has delivered every center fuselage on time and continues to meet its cost and schedule commitments. In 2011, the company delivered 22 center fuselages and is on track to deliver 32 center fuselages this year. It will make its 100th delivery in early 2013.

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The purchase order covers the manufacture and delivery of composite carbon fibre wing flaps for 24 Lockheed Martin C-130J Hercules aircraft. The work is to be undertaken at the companies Bankstown aerospace facility recently established by Quickstep.

The order is valued at US$12 million and deliveries are expected to commence December quarter of 2013 at an approximate rate of two sets per month. The order is in addition to the initial purchase order from Lockheed Martin for preliminary work announced in August 2012, which is expected to be completed prior to the first delivery of parts.

Each set of wing flaps comprises four parts with an aluminium structure and skins of carbon fibre composite, providing light, strong components capable of great endurance and longevity.

The purchase order is part of an overall agreement with Lockheed Martin expected to generate Quickstep revenues of between US$75 million to US$100 million over five years. Since initiation, more than 2,400 C-130 aircraft have been built in the longest continuously operating military aircraft production in history.

The Lockheed Martin C130-J flap program is the second aerospace program awarded to Quickstep, following its contracts to produce components for the F-35 Lightning II Joint Strike Fighter program. It is expected to generate up to $700 million in revenues for Quickstep over the next 20 years. Quickstep expects to be one of the largest Australian contributors to the JSF Program.

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The order covers preliminary work such as planning, tooling and training activities which are already underway. This component of the contract is expected to be valued between $1.4 million to $1.6 million and will be completed prior to the first delivery of parts.

Together with the recent approval of an export licence, these activities pave the way to finalising the long term agreement with Lockheed Martin. The agreement is estimated to generate revenues of $75 million to $100 million for Quickstep over the next five years.

Quickstep will prepare to manufacture initial components. First delivery of parts is expected in the first quarter of 2014, in line with global supply chain delivery arrangements.

The company currently work with several of the world’s largest aerospace companies and have just recently opened a new composite manufacturing facility in Sydney.

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