COMPOSITE COMPONENTS FOR THE EXPEDITIONARY FIGHTING VEHICLE (EFV)
Teaming with Material Sciences Corporation as the lead, MSC/SCI has completed a Phase I and Phase II SBIR grant to conduct research for weight savings on the Marine's EFV being built by General Dynamics. SCI has successfully fabricated full size parts for the exterior of the vehicle with the goal of saving weight over the existing metallic components. SCI's success has been measured by the award of a Phase III program where SCI has built preproduction hardware for 4 vehicles. The primary components being built are the bow flap and the chine flaps.

For the bow flap, the team achieved a weight savings of 25% over the aluminum base line. It is a carbon fiber reinforced/toughened epoxy sandwich that has an integral composite hinge. The bow flap extends forward on the vehicle in water mode and is subject to extremely high wave slap loads. The complex core assembly is designed to distribute load from the actuator pads throughout the structure. The composite chine flaps achieved a 43% weight savings over the highly optimized high speed machined aluminum chines. The composite chines are S2 glass/vinyl ester sandwich structures, and although their primary use is to cover the tracks in water mode, the highest loading they see is the land mode when they are tucked up under the belly of the vehicle. The composite chines have been tested in land mode and with a simulated mine blast.

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