Vertically-aligned carbon nanotubes (VACNTs) will be selectively applied at interfaces in laminated composite structures to effect locally the mechanical properties that limit rotorcraft structures, such as fatigue and damage tolerance. In Phase I this work will quantify these effects in CFRP and CFRP/GFRP hybrid coupons. The VACNT material will be transferred directly onto prepreg plies, but also introduced using a compatible resin film as a vector. Both standard coupons and tapered (ply-dropped) coupons will be evaluated. Analysis of failed coupons will associate damage modes with VACNT properties and integration schemes. Success in Phase I will achieve significant increases in interface dominated laminate properties at the coupon level, combining VACNT local reinforcement with incumbent fiber/resin systems. During Phase II these benefits will enable both enhanced durability at the component level e.g., flexbeam, rotor; as well as increased design freedom to enable more structurally-efficient and/or compact structures. N12 Technologies produces large format VACNTs at scale for composite applications, and will partner with University of Dayton Research Institute to perform the fabrication, testing and analysis of VACNT-reinforced coupons.
Benefit: N12 Technologies will develop VACNT-enhanced carbon fiber prepreg and/or resin films for sale to OEMs within the rotorcraft market. In addition, based on the development through the STTR, N12 also sees opportunities within other markets that include aviation (e.g. commercial), consumer goods (e.g. sporting equipment), space, automotive, and medical (e.g. prosthetics). These VACNT-enhanced products will advance the industries that adopt them, and lead to superior, tougher, longer-lasting, and damage resistant products. The combined impact of localized application of VACNTs to improve damage tolerance and durability within rotorcraft is valued at $200M for future unit purchases. Expending the application to commercial aircraft, consumer sporting goods, and prosthetics, the annual demand could be in the range of $400M to $450M. By leveraging the data from the STTR, N12 would be able to target localized applications and fast track active programs with aerospace and consumer product OEMs to adopt localized application of VACNTs. The consumer market would be the quickest to adopt due to shorter design and development cycle of 2 - 5 years, while aerospace could take up to 10 years to adopt the technology. The company has invested heavily in building out its VACNT product capacity and has sufficient capacity to meet the anticipated demand for localized VACNT application by rotorcraft. Furthermore, the company will be able to ramp up VACNT manufacturing capacity as demand from commercial aerospace and consumer goods increases. Military Rotor Craft Localized and Damage Resistant Product Opportunity Size: Based on N12s analysis, the company estimate the localized composite market for a 5% application area for rotorcraft carbon fiber components to be at least $200M for the four principal existing rotorcraft programs used by the military. The estimate is based on planned purchases by the military and does not factor retrofit of current rotorcrafts in service. The current rotorcraft in service could benefit from localized VACNT application in blades and potentially double the market opportunity. Commercial Aviation Localized and Damage Resistant Product Opportunity Size: In addition to rotor craft application, we estimate the commercial aviation market would also benefit from applying localized VACNTs to improve damage resistance and increase toughness. Based on Boeing and Airbus 20-year forecast (2018-2037), total commercial aircraft deliveries by 2037 will number 37,389 of which 36,563 will be 100+ seat commercial airliners with the remainder allocated to freighters (826). Based on Airbuss estimates, over 40% of aircraft deliveries will occur in the Asia Pacific region, while North America and Europe will each represent 15% and 19% of deliveries, respectively. Airbus estimates the total value of deliveries will represent over $5.5 trillion during the 20-year time horizon. N12 has been working with select OEMs for the last five years and has active programs testing VACNTs which will allow the company to expand its working knowledge. The company estimates the addressable market for localized VACNTs applications on wings and tail areas could grow to $380 million per year, where 50% of unit deliveries using carbon fiber components. Other markets that would benefit from localized and damage resistant applications size: The company has worked with consumer products OEM, representing end markets such as performance bicycles, golf clubs, baseball/softball bats, tennis racquets, and hockey sticks; space launch vehicles; and industry leaders in prosthetics. On a test scale basis, N12 has demonstrated a material improvement in damage tolerance in a combination of prepregs across different consumer end markets, while engaging in limited testing in the prosthetics market. Based on our customer interaction, sporting goods OEMs would be able to incorporate the material into their high-performance product lines at a sufficient low price point of N12s VACNTs. According to Technavio research, the global demand for carbon fiber prepreg is expected to reach $4Bn by 2021 and is growing at a rate of 10.5% per annum. By 2021, sporting goods and prosthetics, amongst other niche market, will represent approximately $1Bn of the overall prepreg market. A localized application of 5% to 10% of applicable area would represent a $35M to $75M annual opportunity.
Keywords: CNT, CNT, Composites, Fatigue, VACNT, Damage Tolerance, carbon prepreg, nano, Durability
