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Radomes and Composite Shielding

Radomes are designed to protect antennas at subsonic to supersonic speeds with minimum interference to radar transmission.  Using advanced composite materials when designing and manufacturing various types of radomes such as blade, low-profile, and ballistic radomes provides numerous advantages such as:

  • Low dielectric properties (fibers and resins)
  • Low loss tangent
  • Increased stiffness with lower weight
  • Special Coatings
  • Thermal Stability

Typical composite material used:

  • E-Glass
  • S-Glass
  • Quartz
  • Spectra Shield®

Typical resin systems used:

  • BMI
  • Cyanate Ester
  • Epoxy

Royal Plastic manufactures composite radomes to precise specifications and can assist in selecting the appropriate radome for your application.  All radomes are designed using advanced composite materials that optimize performance for the required application.  Large radome designs feature specially designed composite structure where applicable to enclose radar units.  The composite structure can be solid wall, multi-layer,  sandwich construction or even have reinforcing ribs.  Small radomes feature additional technology such as Rohacell® foam technology.  Radome design and construction can be tailored to minimize loss at specific frequencies with optimum strength.  Numerous topcoats are available including epoxies, polyurethanes, fluoroelastomers, hydrophobic and anti-static coatings.  Specialized mounting hardware such as captive fasteners and lightning diverter strips can also be supplied.

Space Applications and Satellite Components

The above are examples of satellite receivers, transmitters and shielding covers for satellite equipment.

Copper circuits are embedded in the composite part to make a light weight platform for space applications.  The above shown parts are fabricated from quartz fiber reinforcement with a cyanate ester resin system.  These products are photographed before and after an elevated cure, which enables these parts to have a 500° F service temperature.

Shown to the left is a S-Band transmitter that is 18.0" in length.  Royal has manufactured S-Band transmitters up to 4.50 feet in length.

Also shown above is a housing unit for satellite optics.  This particular example is extremely accurate and maintains surface and positional requirements of +/- .005" throughout the entire part and has been qualified through a 9G vibration test that simulates spacecraft launch.

Additional features for satellite components:

  • High strength to weight ratio - Composites weigh 32% less than aluminum and the fibers can be orientated to maximize performance.
  • Composite structures also provide improved strength and stiffness to weight performance versus conventional fabricated aluminum structures.
  • Radar Transparency - Various glass fibers and organic matrix are relatively invisible to radar or microwave transmissions.
  • Durability - Composites provide high abrasion and impact resistance while offering improved fatigue life.
  • Special Operations - High performance composites can operate under extreme conditions, temperatures and pressures.
ECS Ducting

The above shown ECS ducts are fabricated from Kevlar® and carbon fiber with an epoxy resin system, utilizing a ultra low weight design for optimum performance.  The carbon fiber ducting shown above center, incorporates a specialized design for military helicopter airframe platforms.  This new ducting utilizes proprietary technology to create graphite fiber composite ducts capable of zero leakage performance and with a wall thickness of only 0.013".  Stringent requirements on internal air flow temperature dictate the addition of low density, low thermal conductivity insulation blankets on many of the ducts.  This ultra low weight design package featured over 70 total parts with a combined  weight of less than 17 lbs.  These ducts consistently outperform a lengthy list of standard military specifications.

The above shown are specially insulated ECS ducts that are fabricated from a polyester resin system with fiberglass reinforcement.  This ducting system is designed for use in a restricted envelope environment, utilizing a low profile aerospace insulation for optimum performance.  This ducting package incorporates a specialized design for retrofit on military surveillance platforms.  These ducts are engineered to consistently outperform  standard military specifications.

Secondary Aircraft Structure

The above shown secondary aircraft structures enclose radar equipment and are constructed of carbon fiber (graphite) with an epoxy resin system.  These aircraft fairing units are designed to operate up to 290° F temperature requirement.  Tolerances of +/- .005" are maintained.  The center example is an flight surface door to enclose and protect avionics equipment.  The left and right examples are  leading edge fairings that meet stringent structural requirements.  Royal Plastic transitioned these fairings to meet specific engineering requirements and performed full FEA analysis and composite design engineering through full production.  Specialized fasteners can be incorporated into any composite fairing design.  Also many specialized coatings, such as hydrophobic or static dissipation coatings are available for demanding product applications.  Also shown is a carbon fiber exterior access door for avionics.  Numerous pieces of custom hardware, including static dissipation strips, locking quick release fasteners and high tolerance attachment hinges were fabricated for this application with specialty coatings applied to protect against corrosion.

Flexible Composites

Flexible composites can provide flexibility while maintaining strength and durability.  In addition flexible composites can meet or exceed FAA flammability and smoke emission requirements while providing solutions to unique applications.  In most applications, ply's or layers of a flexible elastomer or rubber are reinforced with an advanced composite cloth to create a strong yet flexible product.

Available types of elastomers:

  • Silicone - FED STD ZZ-R-765 - Royal Plastics standard rubber.  Silicone weathers well and has low smoke emission in a fire.  Typical applications involve a service temperature up to 500° F.  Silicone is resistant to high and low temperatures and aliphatic solvents, oils and greases.
  • Neoprene - Best resistance to aircraft fuel and oil, ozone, sunlight, gasoline, aromatic or halogenated solvents.  Easily permeated by water.  Typical application involves a medium range service temperature with less stringent smoke emission requirements.
  • Nitrile - Good resilience, abrasion resistance and low heat build up.  Resistant to oils, hydraulic fluids and most hydrocarbons.  Typical application involves a medium range service temperature.
  • Fluorinated - Highest overall cost.  Often used in specialty applications.  Chemical resistance is similar to silicone with improved resistance to fuel, aromatic and chlorinated solvents.  Weakness with ketones and hydrazine.
  • Butyl - Good resistance to dilute mineral acid and alkali concentrated acid, except nitric and sulfuric acid.  Good ozone resistance.  Typical application involves a medium range service temperature.  Resistant to oils, hydraulic fluids and most hydrocarbons.

Available reinforcements:

  • Fiberglass - High strength, low cost
  • Nylon - Maximum flexibility
  • Nomex® - Flame resistant material
  • Cotton - Lowest cost

For technical design specifications and additional information on Royal Plastic Mfg., Inc, line of flexible composites, custom designed hoses or composite ducting for aerospace applications please click here...

 

Filament Wound Structure

 

Filament Winding is a major manufacturing process in the fabrication of high performance polymeric composites, allowing the process of filament winding to be the most efficient and least expensive method to construct the basic infrastructure systems.  Filament winding adds material to a shape forming structure, using high strength to weight and stiffness-to-weight properties that characterize continuous filaments of advanced composite materials.  By using filament wound processes applications never corrode and remain maintenance free for decades, competing in cost and performance with metallic structures.  Filament winding is a time-tested process that is not only versatile but continues to be improved by use of information technology and mathematical analysis so the precise and useful manufacturing and product design parameters are provided to the engineers and managers who must make decisions relating to cost and performance.

Continuous fiber reinforcement, provides the structural performance required for the final part. The fiber is the primary contributor to the stiffness and strength of the composite

Available continuous fiber reinforcements:

  • Fiberglass fiber
    • E-Glass - High strength (400-500 ksi), low modulus (10.5 msi), lowest cost fiber, available in many forms, widely used in commercial and industrial products
    • S-Glass - Improved strength (625-665 ksi), higher modulus (12.6 ksi), higher cost fiber, used in aerospace and high performance pressure vessel applications.
  • Carbon / Graphite Fiber - Increased performance, wide strength range (270-1050 ksi), highest modulus (33-120 msi), highest fiber cost, intermediate density, poor impact or damage tolerance, best tensile strength and stiffness properties.
  • Thermoplastics - Including Spectra Shield® with ballistic properties
  • Aramid fiber - Good strength (450-550 ksi), higher modulus (11.5-27.0 msi), higher cost fiber, very low density, excellent impact and damage tolerance properties, poor compression and shear strength.
  • Kevlar®

The resin matrix provides the load transfer mechanism between the fibers onto the structure. In addition to binding the composite structure together, the resin matrix serves to provide the corrosion resistance, protects the fibers from external damage, and contribute to the overall composite toughness from surface impacts, cuts, abrasion, and rough handling. Resin systems come in a variety of chemical families, each designed to provide certain structural performance, cost, environmental, and/or environmental resistance. 

Available resins:

  • Polyester

    • General purpose polyester - Orthophthalic polyesters, lowest cost systems, widely used in FRP industry, moderate strength and corrosion resistance, room temperature cure.

    • Improved polyester - Isophthalic polyesters, slightly higher cost, good strength and corrosion resistance, widely used in FRP corrosion applications, room temperature cure.

  • Vinyl Ester -  Chemical combination of epoxy and polyester technology, excellent corrosion resistance, higher cost, excellent strength and toughness properties, widely used as corrosion liner in FRP products.

  • Bisphenol-A, Fumarate, Chlorendic - More exotic systems for improved corrosion resistance in harsh environments, higher cost resins, higher temperature capability, sees application in paper and pulp industry applications.

  • Phenolic - Excellent flammability properties (eg. flame retardance, low smoke emissions), higher cost systems, lower elongation, moderate strength, applications involve fire resistant systems structures.

  • Epoxy - Wide range of resins available, best strength properties, usually heat-cure required, good chemical resistance, higher viscosity systems, higher material cost, applications across broad market segment range.

Royal Plastic can design and manufacture a lightweight, high performance tubular structures for any application in the Aerospace, Medical, Oil and Gas and Commercial Roller Markets. Specific technologies include; low TIR, low inertia and high stiffness custom rollers, high torque drive shafts, thick-walled flywheels and extreme pressure vessels.

The above shown filament wound application is an ultra high pressure tube for use in a environmental testing facility.  It is constructed out of high-modulus graphite fibers with an epoxy resin system.  Wall thickness is .750".  No liners are incorporated into this composite tube design.  This ultra high pressure tube has been tested to 22,000 ps.i. before failure.  Also shown is an ultra high pressure vessel that incorporates a metallic liner system rather than a standard thermal insulation system used to contain the pressurizing medium.

Interior Components

Royal Plastic manufactures composite aircraft interior components to precise specifications and can assist in selecting the appropriate design for your application.  All interior components are designed using advanced composite materials that optimize for weight savings and performance.  Some interior components feature additional reinforcement or localized metallic reinforcement to aid in increasing the structural strength properties.  Numerous topcoats are available including standard matte finishes and anti glare coatings.  Specialized mounting hardware can also be supplied.

Rigid Ducting

Royal Plastic manufactures a variety of rigid composite ducting utilized on multiple aircraft platforms. 

Advantages of rigid advanced composite ducting:

  • Diverse product applications for low-temperature, oven cure polyester and epoxy ducts
  • Fire-resistant phenolic ducts for high performance applications
  • High-temperature autoclave cure cyanate ester or bismaleimide ducting for operations in extreme temperature or pressure requirements.
  • Improved conformance to flame, smoke, or toxicity requirements
  • Durability and exceptional corrosion resistance

Rigid ducting can be used to supply cooling air to avionics or to remove waste media from various aircraft components.  Rigid composite ducting can be designed to operate at a specifically required flow rate while retaining necessary fit tolerances or clearance in restricted envelope environments.  Rigid composite ducting can also be supplied with or without flexible cuffs to compensate for slight misalignment upon installment in the aircraft.

Composite Covers

Royal Plastic manufactures advanced composite covers for interior and exterior aircraft surfaces.  These cover seal out moisture and contaminants, protecting sensitive equipment and providing easy access for maintenance when needed.  Advanced Composite covers can be designed with protective finishes to further protect against premature weathering or environmental damage.  Specialty hardware such as captive fasteners, cam-lock fasteners, safety cables, lanyards, and safety placards can also be attached as required.

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