Composites : Triumph Aerospace Systems - Newport News

Triumph Aerospace Systems - Newport News has a long history of engineering composite material solutions for classified military programs and prototype parts for larger programs. Our composite materials engineering team has supported many aerospace development programs by supplying innovative prototype solutions to meet ground test and flight hardware testing needs. We are experienced in working with fiberglass, graphite and Kevlar materials (both cloth and pre-impregnated) to fabricate custom complex composite structures. Tooling approaches range from templates to CNC-machined forms, mandrels and molds made from wood, high-density foam, fiberglass, aluminum, steel or graphite. Curing techniques include the use of autoclaves or ovens.

Tooling

Triumph Aerospace Systems – Newport offers a full range of tooling capabilities, from low-cost wood and Ren Shape to high-temperature composites and Invar. We routinely conceive, design, fabricate and implement a variety of precision tooling for composite lay-up and curing. Our design engineers, manufacturing engineers and fabrication team work within an Integrated Product Team (IPT) to optimize the tooling designs and fabrication processes.

• Tooling Materials
  • Composites
  • Woods
  • Metals
  • Foams

Layup Process

• Pre-Layup:
  • Ply Cutting/Kitting
  • Core Forming & Sculpting
  • Core Machining
  • Core Materials:
    • Aluminum and Aramid Fiber Honeycombs
    • Rohacell PMI & Polyurethane Rigid Foams
    • Balsa
    • Various specially treated Honeycombs and Foams
• Layup:
  • Fibers: Graphite, Kevlar, Astroquartz, S2 Glass, Fiberglass
  • Resins: A variety of low to high temperature thermoset cure epoxies. 
  • RAS Materials

Composite Resources

• Freezers for material storage (4)
  • Up to 12’x8’
  • Equipped with calibrated temp. recorders and alarms
• Autoclave (5.3’x11’, 500 degrees Farenheit, 100psi)
• Curing Ovens (28’x13’x8’)
• Clean Rooms (3,500 sq ft)
  • Temp/Humidity controlled
  • Meets ASTM F25 particle count requirements
• Platen Press
• 5-axis High Speed Router
• Secure Vaults (12)

Previous experience with Composites includes:

• Submarine Tail Cones
• ISS Exhaust Mufflers
• Radar Absorbing Structures
• Jet Stream Tubes
• Oil Cooler Ducts
• CMWS Fairings
• IR Suppressor Systems
• UAV Engine Cowlings
• Rotorcraft Test Stand Structural Frames
• Submarine Sail Cusps
• Helicopter Blades
• Full-Scale RCS Models
• Various RCS Test Devices