Materials

Titanium/Composites Brazing

Morgan Advanced Materials (Windsor, UK) announced that it now has the capability to braze carbon fiber, ceramics, composites, or other engineered materials directly to a titanium honeycomb. Carbon fiber and other similar non-metallic engineered materials have exceptional thermal conductivity capabilities, and are able to remain strong at temperatures exceeding 2000°F, far higher than those at which any metals retain their strength. Titanium honeycomb adds greater strength to the carbon fiber and eliminates fracturing issues by transferring forces from impact better than the carbon fiber alone. Both materials are exceedingly lightweight.

In addition, the strength of the braze bond is exceptional, equaling or exceeding the strength of each component material, unlike the reduced strength of adhesive, riveted, or other bonds. The addition of the titanium honeycomb to the carbon fiber allows easy joining of the titanium to other structures through traditional joining techniques.

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Posted in: Products, Defense, Consumer Product Manufacturing, Materials
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Advancing the Use of Beryllium Bearing Materials for Unmanned Platforms

Aerospace and defense platforms are often regarded as the earliest adopters of new materials and processes technologies. Materials test programs provide validations of material supplier property claims, as the physical tests are performed and data is analyzed. Resultant material “design allowables” are developed and compared to the performance envelopes for the intended application(s). The quality of simulation software and the developed knowledge base that design and strength engineering personnel use for analyzing materials in the intended product design and environments have improved dramatically in the last decade. This has primarily been based on the efficiency and availability of computing capacity for complex simulations.

Posted in: Articles, Aerospace, Defense, Materials, Simulation Software, Test & Measurement, Beryllium alloys, Unmanned aerial vehicles
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Unlocking the Power of Ceramic Matrix Composites

Faster, lighter, stronger, hotter – words anyone working on military product development is all too used to hearing. In a world where advanced computer modeling and simulation packages are helping engineers optimize new product designs to increase performance, oftentimes the limiting factors to meeting spec are the mechanical and thermal restrictions inherent to currently available engineering materials. Ceramic matrix composites, or CMCs, provide an entire world of new thermo-mechanical properties, allowing engineers the ability to unlock the potential of some of their most advanced high temperature and high speed designs.

Posted in: Articles, Aerospace, Defense, Ceramics, Composites, Materials, Ceramics, Composite materials, Military vehicles and equipment
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Toho Tenax Develops 'Super-Heat-Resistant' Prepreg for Engine Apps

Toho Tenax Co., Ltd. announced Nov. 6 that it has developed a new prepreg — a carbon-fiber sheet pre-impregnated with matrix resin — that offers super-high-heat and -oxidation resistance suited to aircraft and automotive engine compartments.

Posted in: Technology Update, Aerospace, Defense, Materials, Composite materials, Fibers, Resins, Engines
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Embedded Switch Fabrics

Mercury Systems, Inc. (Chelmsford, MA) has announced its Micro Via Radial Interconnect (MVRI) technology. MVRI improves OpenVPX™ switch fabric interconnect data rates by increasing the signal integrity margin approximately three-fold, enabling switch fabrics and point-to-point connections to run faster and more reliably. MVRI technology is scalable, enabling it to support signaling rates greater than 14 wGbaud per channel. Planned future fabric implementations, using InfiniBand enhanced data rate (EDR) or 100Gb Ethernet, especially benefit from the performance boost MVRI technology delivers. Intel® Xeon® server-class OpenVPX ecosystems in combination with the latest InfiniBand and Ethernet switch fabrics provide the embedded processing capability needed for challenging electronic warfare (EW) and C4ISR processing applications.

Posted in: Products, Aerospace, Defense, Electronics & Computers, Materials
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Infusing Lightweight Composite Structures

European researchers examine simulation-based solutions for the manufacture of large-scale, liquid-resin-infusion composite substructures.

Liquid resin infusion (LRI) is a proven manufacturing technology for both small- and large-scale structures for which, in most cases, experience and limited prototype experimentation is sufficient to get a satisfactory design. However, large-scale aerospace and other vehicle structures require reproducible, high-quality, defect-free parts with excellent mechanical performance. These requirements necessitate precise control and knowledge of the preforming (draping and manufacture of the composite fabric preforms), their assembly, and the resin infusion.

Posted in: Articles, Aerospace, Defense, Composites, Materials, Forming, Composite materials, Lightweight materials, Resins
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Continuous Sputter Deposition Coating of Long Monofilaments

A thin, uniform coating on long segments of monofilament could drastically improve the functionality of many complex fibers. A length of fishing line, microtubing, or polylactic acid (PLA) coated with copper could be left to cure within an epoxy, and upon removal of the monofilament, a narrow channel with a thin outer wall of copper would remain. That channel would be open for fluid flow, and also have a conductive shell. The “vascularized” material could be used for thermal management or self-healing composites.

Posted in: Briefs, Aerospace, Defense, Coatings & Adhesives, Materials, Thermal management, Adhesives and sealants, Coatings Colorants and Finishes, Copper, Fibers, Hoses
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Hydrolytic Stability of Polyurethane-Coated Fabrics Used for Collapsible Fuel Storage Containers

Collapsible fabric fuel tanks have provided critical tactical bulk petroleum storage for military operations for over 50 years. Beginning in the 1940s with the 900 to 3,000-gallon pillow tanks, collapsible fabric tanks have evolved into the primary tactical fuel storage vessels now used by all of the military services.

Posted in: Briefs, Aerospace, Defense, Coatings & Adhesives, Materials, Containers, Storage, Coatings Colorants and Finishes, Fabrics, Fuel tanks, Military vehicles and equipment
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Materials Design Principles for the Dynamic Fracture of Laminar Composite Structures

Crack bridging (e.g., from stitches or pins) and friction have profound and potentially very useful effects on delamination crack growth, controlling growth rates (damage levels) and the energy absorbed. However, the implications for structural design principles have remained quite obscure. The difficulty is that no simple analogue of crack toughness, which underpins static structural design, exists for dynamic cases with large-scale bridging effects. The external shape of the structure and the loading configuration dictate stress waves, frictional contact zones, and crack tip stress intensity factors in a way that is very difficult to approach, other than by brute case-specific numerical simulation. The problem is compounded by the common occurrence of multiple cracking, a complexity that is rarely entertained in laboratory fracture specimen design. Physically sound material models for the important structural problem of multiple, nonlinear cracking in laminated structures with large-scale bridging due to friction and reinforcement had previously remained undeveloped, in spite of the technological importance of these systems.

Posted in: Briefs, Aerospace, Defense, Electronics & Computers, Information Technology, Materials, Finite element analysis, Composite materials
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Development of Hydrophobic Coatings for Water-Repellent Surfaces Using Hybrid Methodology

Coatings that impart hydrophobic properties are of considerable interest. For applications such as aircraft windows, optical components, protective eyewear, and clothing, this type of surface is desired for the material to be soil-repellent and waterresistant. A prime model of a surface with these characteristics can be found in nature – the leaves of the lotus flower have super-hydrophobic properties as a means of self-cleaning.

Posted in: Briefs, Aerospace, Defense, Coatings & Adhesives, Materials, Windows and windshields, Optics, Coatings Colorants and Finishes, Protective equipment
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