SBIR-STTR Award

Composites offer significant weight saving potential in engines, which is of great interest to programs like the X35 JSF and F136 engine. A composite F136 Front Frame offers the AF the potential to save 30 pounds on the JSF alternate engine. Complex composite assemblies made conventionally have been expensive, and cost reductions are needed to insert more composites on engines. Automated fiber placement can provide significant cost savings. Braiding is a proven and cost-effective automation method that is inherently well-suited to many engine part configurations. RTM for engine parts is limited because of the process characteristics of high temperature resins like PMR15. The SARTM process (a subset of RTM) has been developed to enable PMR15 and other high temperature resins to be used for high temperature engine parts. A combination of braiding and SARTM offers the potential to realize weight savings for a fully functional part at a significantly lower cost than present manufacturing methods. FII, in cooperation with GEAE (the engine prime), shall demonstrate the feasibility and potential benefits to accrue to the F136 JSF engine using a low-cost braided front frame. The program has direct benefit to a major DoD program and significant commercial potential. Benefits anticipated from this work include realization of a 30 pound weight saving on the F136 engine and a significant cost reduction versus present SOTA composite manufacturing methods. This will be supported by a well-documented trade study to identify various design options and downselect on a sound technical basis with the full participation of the engine prime contractor. A proof-of-concept part shall be produced to demonstrate feasibility and reduce risk of the selected design approach, leading to a solid basis for further development in Phase II. Successful demonstration of this technology can lead to similar applications in both military and commercial engines, offering a very broad path for commercialization.

Composites offer significant weight saving potential in engines, which is of great interest to the F-35 JSF aircraft and its F136 engine. A composite F136 Front Frame offers the potential to save 20 pounds on the F136. Complex high temperature composite parts made conventionally have been costly, and cost reductions are needed to use such parts on engines. Automated fiber placement such as Braiding provide significant cost savings. Braiding is a proven and cost-effective method that is inherently well suited to many engine part configurations. To date RTM processing for engine parts has been limited by process characteristics of high temperature resins like PMR15. Recently resins with excellent high temperature performance and process characteristics suitable for RTM have been developed. The combination of Braiding and RTM has been demonstrated in Phase I to offer a lighter frame than the present titanium frame at cost parity (i.e. no cost penalty). Fiber Innovations, in close cooperation with GEAE (the F136 prime), shall design, develop and test a full scale Frame component to validate weight and cost benefits on the F136 JSF engine using a low-cost braided Front Frame. The program has direct benefit to a major DoD program and significant commercial potential.

Keywords:
Braiding, Rtm, Front Frame, High Temperature Resin, Pmr15, Anti-Icing, F136 Jsf Engine, Affordability