PHYSICAL SCIENCES INC. — Department of Defense SBIR Phase I: MDA20-009

Description

Physical Sciences Inc. (PSI) proposes to demonstrate a Direct Z-Pin Insertion (DZI) process for local application of 3D reinforcements in high temperature composite structures (2000F-4500F). The DZI process inserts rigid composite pins normal (through thickness) to a 2D composite preform prior to cure. The pins act to improve both interlaminar tension and shear strength in the final composite structure. During the Phase I program PSI will demonstrate the DZI processes will preserve in plane mechanical properties while improving interlaminar and shear strength of a 2D laminate by at least a factor of two. We will perform an economic analysis showing that localized Z-pinning can be a cost effective, production ready technique for reducing erosion as a result of aerothermal shear in hypersonic vehicle bodies constructed from high temperature composites. Working with a vehicle integrator and the government, we will identify a subelement structure and test conditions to demonstrate the effectiveness of Z-pinning reinforcements in hypersonic flight conditions during a follow-on Phase II program. Approved for Public Release | 20-MDA-10643 (3 Dec 20)