SBIR-STTR Award

Advanced composite materials for Energy Regeneration for Improved Vehicle Efficiency
Award last edited on: 1/11/2022

Sponsored Program
SBIR
Awarding Agency
DOD : Navy
Total Award Amount
$1,638,524
Award Phase
2
Solicitation Topic Code
N162-079
Principal Investigator
Dale Tiller

Company Information

Pacific Engineering Inc

1074 Saltillo Road
Roca, NE 68430
   (402) 421-3999
   N/A
   pacificengineeringinc.com
Location: Single
Congr. District: 01
County: Lancaster

Phase I

Contract Number: M67854-17-P-6531
Start Date: 12/21/2016    Completed: 3/20/2018
Phase I year
2017
Phase I Amount
$149,550
The output of this Phase I will be several lighter weight ACV 1.1 potential candidates, these include components within the land and marine propulsion systems (drive shafts and propeller), hull shapes (bow vane and stern/trim flaps) as well as doors, hatches, inlet grill, exhaust ducts and grills. These components will take advantage of the ideal properties that composite has to offer: lightweight, high specific strength, inherent corrosions resistance, limited constraints in shape and contour. To minimize un-sprung weight and provide the requisite strength/stiffness, in the propulsion system we anticipate the use of composite drive shafts for the wheels and propellers. For the propeller blades and shrouds we anticipate using Sandwiching a low-density, lightweight foam core material between thin face sheets can dramatically increase a laminate's stiffness to match a metallic part with decrease in weight. A sandwich structure is also cost-effective because the relatively low-cost core replaces the materials that would be used to produce a thick laminate. PEI will also investigate using hydrophobic coatings with nano additives on composite shrouds, bow and stern planes surfaces to improve abrasion and impact damage resistance as well as reduce drag. Significant drag reduction has been measured in turbulent flows over hydrophobic surfaces.

Benefit:
The benefits of PEI SBIR Phase I is the transition of advanced composites and nano-coatings technologies to achieve significant weight savings and improved water and land performance for the Amphibious Combat Vehicle (ACV) 1.1. Specifically, PEI designs and development of drivetrain components such as composite drive shafts and props as well as evaluating the use of light weight composites for the propeller assemblies, shrouds, doors, exhaust components, bow vanes and stern flap will increase ACV performance. The weight savings brought about through the use of composites, approximately 70% vs. steel and 30% vs. aluminum, will yield a reduction in vehicle weight as well as an increase in operational performance. This includes increased fuel efficiency, mobility and buoyancy. Composite structures are also able to absorb and dissipate vibrations (and other harmonics), are inherently insulative (to noise and heat), and are much safer than metals when they do fail. Finally, composites are intrinsically resistant to corrosion which makes them ideal for use in the AAV operational environment. The combination of reduced weight, longer life, and corrosion resistance enhances the maintainability and affordability.

Keywords:
Drive Shafts, Drive Shafts, Modeling, Light weight, High Strength, Materials, Composites, Propellers, molding

Phase II

Contract Number: M67854-18-C-6527
Start Date: 3/23/2018    Completed: 9/22/2019
Phase II year
2018
(last award dollars: 2020)
Phase II Amount
$1,488,974

This Phase II project goal is to develop solutions that improve the fuel efficiency of Amphibious Vehicles. Amphibious vehicles operate on the leading edge of an assault and in environments where ongoing access to fuel is limited. More efficient fuel usage will also enable longer mission durations and increased operating ranges. The goal is to reduce fuel usage over the Amphibious Vehicle mission profile by 10 to 15%. These vehicles must also operate in harsh environments, including water and off-road conditions. Solutions that reduce weight, particularly un-sprung mass, can improve fuel efficiency while also improving ride quality and water performance. Reducing vehicle weight through composite components favorably reduce ship draft, allowing the AV to ride higher in the water, reducing both pressure and frictional drag. The preliminary assessment of weight saved is conservatively estimated to be ton. This would reduce the vehicle drag by approximately 1.33% (each pound of weight savings will result in 0.0374 lbs. of drag reduction). Using composite materials for the design and fabrication of structures can provide desirable benefits beyond just saving weight; they most benefit in AAV in extreme environments (high stresses, fatigue, multi-axial loading, high and low temperatures, corrosive environments).

Benefit:
MCSC and PEO Land needs technologies that can meet load and terrain requirements for AAVs during their performance of its mission that could result in significant fuel savings. PEI is proposing to use composite components that reduce weight, particularly un-sprung mass, and can improve fuel efficiency while also improving ride quality and water performance. PEI has identified components that directly can improve ride quality and also reduce heat into the crew compartment during the transit and also while the vehicle is idling. PEI has the capability to design and fabricate the prototypes being proposed The fuel efficiency improvements prototype(s) will be evaluated to determine its capability in meeting the performance goals defined in this Phase II and specific provided by the Program Of Record. System performance will be demonstrated during the Phase II through prototype evaluation, modeling and simulation and analysis over the required range of parameters. PEI will also prepare for LRIP and create transition plans that reduce risks and allow the new components merge onto the POR.

Keywords:
High Strength, Light weight, filament winding, Drive Shafts, Composites, non corrosive, Structural panels