INFUSED CARBON NANOSTRUCTURES - Lockheed Martin

Lockheed Martin MS2
1801 State Route 17C
Owego,
Lockheed
NY
Martin
13827,
Corporation
USA
www.lockheedmartin.com
6801 Rockledge Drive
Bethesda, MD 20817
Copyright
www.lockheedmartin.com/nano
©2013 Lockheed Martin Corporation
All rights reserved
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©2013 Lockheed Martin Corporation
All rights reserved
3/2013
CET201302014
GS9509
INFUSED CARBON
NANOSTRUCTURES
MANUFACTURING SOLUTIONS FOR
NEXT-GENERATION PRODUCTS

Lockheed Martin’s Applied NanoStructured
Solutions (ANS) subsidiary has created a
process to infuse multi-wall carbon nanotubes
with glass, carbon, and ceramic fibers for
continuous, high-volume production. These
infused carbon nanostructures (CNS) are
versatile platforms for users to create the
next-generation of low-cost composite
materials with enhanced electrical and
thermal conductivity, advanced shielding
properties and protection against lightning
strikes. Low-cost manufacturing processes
and the unique architecture and properties of
carbon nanostructures offer cost-effective,
multi-functional performance across multiple
applications in defense, aerospace, automotive
and commercial applications.
THE POWER OF
CONTROLLED
ARRANGEMENT
ANS engineered its carbon nanostructure materials
to be compatible with established manufacturing
processes, reducing both design and production costs
for end-users. The unique manufacturing process ANS
created thoroughly infuses carbon nanotubes (CNT)
onto glass, carbon or ceramic fiber substrates in a
precisely controlled manner. Unlike materials merely
coated with carbon nanotubes, ANS’ cross-linked
and highly entangled arrangement imparts enhanced
electrical, thermal, and structural properties of
nanotubes to end-products. This is done as one endto-end
production without requiring costly secondary
materials and processes.
The critical infusion of the nanotubes occurs through
an innovative and scalable roll-to-roll process now in
operation at the ANS Pilot Scale Production facility in
Baltimore, Maryland.
ANS works closely with end-users to create a
product-specific, CNT-matrix blend for a user’s select
applications. After developing and validating product
prototypes, ANS will license appropriate patents
and production details to commercial manufacturers
that are configured for their existing production
infrastructure.
For manufacturers, a substantial advantage of the
cross-linked CNS network is that it does not shed or
produce respirable nanotubes that can affect health.
Recognizing that carbon nanostructure technology does
not present an unreasonable risk, the Environmental
Protection Agency has issued a Premanufacture Notice
(PMN) for CNS materials in thermoplastic matrices.
Subsequent PMN’s will follow, as material forms for
specific applications are identified. Lockheed Martin
researchers are also collaborating with the National
Institute for Occupational Safety and Health (NIOSH)
to establish best practices and procedures to mitigate
employee exposure.
Versatility in Action
Lockheed Martin has demonstrated that CNS can
enhance performance of materials used in a wide range
of applications, including:
• EMI and cable shielding
• Lightning strike protection
• Structural health monitoring
• Composite materials for lightweight structural
components
One use of the ANS-engineered carbon nanostructures
is to protect composites in modern aircraft from
lightning strikes. While composite materials provide
many advantages, they can be severely damaged by
lightning strikes. The industry solution to date has been
to add a metal mesh layer to the aircraft design, but
ANS engineers have demonstrated that adding their
carbon nanostructures to aerial composite materials can
provide a light-weight, low-cost alternative to enhance
protection.
The company has also crafted CNS-infused braided
shielding to protect against electromagnetic
interference, using both glass and carbon fiber
substrates. This cabling offers shielding effectiveness
from direct current to 40 Ghz, a 30-70 percent weight
savings compared to standard shielding components, and
costs significantly less than braided copper shielding,
commercial metal-clad fibers, and traditional CNT
materials.
Rapid Reengineering
Lockheed Martin has embarked on a challenge to
redesign the Desert Hawk III unmanned aircraft system
(UAS) using nanocomposite materials. Engineers were
challenged to increase the aircraft’s durability without
increasing the weight of this 8-pound surveillance
workhorse. They used ANS-infused composites to
remanufacture the Desert Hawk’s nacelle and motor
compartment, camera bay, and rear fuselage and tail
assembly. Two redesigned aircraft have received Federal
Aviation Administration (FAA) approval for flight in
commercial airspace. Lockheed Martin engineers will
complete this makeover with CNS composite propellers
and wings. Based on this success, the company plans to
incorporate CNS-infused composites into many of its
UAS platforms, improving their durability, increasing
mission lifetime, and lowering manufacturing costs.