CALE   

Abstract

The goal of this project is to introduce a composite material that can replace aluminum airframe beams in military aircraft. The project sponsor, Northrop Grumman, is exploring ways to reduce the cost of incorporating composites. Carbon fiber reinforced polymer is extremely strong and lightweight, but it is currently very expensive. The team used recycled material to mitigate the high cost of carbon fiber. The team designed three carbon fiber beams with the same strength as a currently used aluminum beam. The first beam uses T300 plain weave carbon fiber; it is the lightest and most expensive. The second beam uses recycled carbon fiber; it is the heaviest and cheapest. The third beam is a mixture of T300 and recycled; the optimal proportions were found by comparing the cost and weight of the T300 and recycled beams. Each beam uses epoxy resin because it is the cheapest material that meets the strength requirements. The beams must provide strength in all operational conditions, such as high temperature, low temperature, vibration, thermal shock, humidity, and salt atmosphere. The team designed and performed a series of tests to validate that the beams are suitable for use in these conditions. The outcome of this project is a method to select, test, and validate composites for use as an airframe component.