The Air Force Research Laboratory’s (AFRL’s) Manufacturing and Industrial Technologies Division and the contractor team of CRG, A&P Technology and CRG’s affiliate, Spintech LLC, conducted research to quantify the benefits of replacing legacy manufacturing processes with novel processes for the fabrication of an 11-foot long, S-shaped engine inlet duct.
The approach replaces the hand-applied composite prepreg with an automated overbraid process which applies dry fiber to a mandrel. The very heavy multi-piece steel mandrel was replaced with a lightweight, single-piece, shape-memory polymer (SMP) mandrel, and the dry braided carbon fiber was processed with a low-cost epoxy resin using a vacuum assisted resin transfer molding process. The team completed analysis of the overbraid architecture, fabrication of a SMP forming tool and construction of the SMP mandrel that will serve as the tool during the preform overbraid process.
One of the primary goals of this program was to understand part cost and production time benefits from introducing the new tooling and processing solutions. The final inlet duct will be delivered to the government for further integration into the Aerospace Systems Directorate’s complementary airframe design and manufacturing program. Personnel at the Aerospace Vehicles Division will conduct static ground testing of the integrated braided fuselage and inlet duct structure. Read full article here.