Archived Defence Sector News - 2008

Editors - please refer to the Notes to Editors for background information on Umeco plc and its operating divisions.

ACG Ballistic Quality Phenolic Prepregs used for Vehicle Metamorphosis to Improve Troop Safety

Schiebel Corporation Chooses Advanced Composites Group Materials for its ‘CAMCOPTER’ UAV

ACG’s Contracts with Swift Engineering to Supply Advanced Prepreg Materials

Zephyr Takes to the Skies with ACG's Composites

ACG Ballistic Quality Phenolic Prepregs used for Vehicle Metamorphosis to Improve Troop Safety - December 2008

Advanced Composites Group Ltd. (ACG), part of the Composites Division of Umeco plc, has entered into a contract that will see the Group supply phenolic prepreg materials for a Ministry of Defence (MOD) project dedicated to improving the protection of British troops serving in urban environments of Afghanistan and Iraq.

Originally ordered by the MOD from Force Protection Incorporated in America, a total of 151 Cougar vehicles will undergo their metamorphosis at Coventry (UK) based NP Aerospace.  Under a £81 million contract from the MOD, NP Aerospace will morph the 4 x 4 Cougar base vehicles into the Ridgbacks by upgrading their armour protection and integrating weapons, communications systems and specialist electronic equipment.  The morphed vehicles will then join their big brother, the Mastiff, on military operations with British troops.

ACG will be involved in the provision of high performance glass phenolic prepreg material to bolster existing vehicle armour and provide improved protection for the occupants and systems in the vehicles.  The high performance glass phenolic prepreg material is fairly new to ACG’s ballistics product range, having been incorporated into their advanced glass and carbon composites product portfolio following the acquisition of George Cole Technologies Ltd (Primco), by ACG’s parent company, Umeco plc, at the end of 2008.

It is understood that the Ridgback will offer a level of protection similar to that provided by its big brother, the Mastiff, but in a smaller vehicle. 

Ridgback and Mastiff protected vehicles, along with the Viking, Bulldog, Warrior, Vector, and Snatch (all currently being used on operations) are variously suited to different threats, terrains and tempos of operation. Together, they give UK commanders the ability to choose the best vehicles for each situation.

Photograph: Copyright Crown Copyright/MOD, image from www.photos.mod.uk

For further details contact ACG Sales Department.

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Schiebel Corporation Chooses Advanced Composites Group Materials for its ‘CAMCOPTER’ UAV - September 2008

ACG recently announced that it has been selected by Schiebel as one of its preferred suppliers of material for its CAMCOPTER® S-100 Unmanned Air Vehicle (UAV).  In particular, ACG’s MMT®49 and LTM®212 prepregs were selected for the manufacture of the UAV’s carbon-fibre monocoque fuselage and tooling.  With strength-to-weight ratio being a fundamental consideration in all aircraft design, it’s hardly surprising that advanced composites materials were selected for the structure of Schiebel’s CAMCOPTER® S-100.

CAMCOPTER® S-100 is a highly versatile autonomous UAV system developed to provide a unique balance between advanced capabilities and operation in tactical environments.  The system consists of a compact helicopter aerial vehicle that can be fitted with a wide variety of payloads tailored to meet diverse user requirements.

CAMCOPTER® S-100 UAV, which measures 3110mm (122in) long x 1040mm (41in) high x 1240mm (49in) wide, with a rotor diameter of 3400mm (133.9in), is capable of carrying a 25 kg (55 lbs) payload for up to six hours.  The UAV is powered by an aviation-certified rotary engine.  The S-100 is also being developed for maritime applications, where it is capable of landing on helicopter deck-equipped ships without the use of additional landing equipment.

ACG’s MTM49 component prepreg is an 80 to 160°C (176 to 320°F) curing, toughened epoxy matrix resin specifically formulated for the manufacture of components requiring excellent ambient and hot mechanical performance combined with good impact resistance. MTM49 exhibits a good balance of temperature resistance and toughness properties, and was considered to be ideal for the application.  In brief, MTM49 accommodates a range of end use temperatures - depending on application and post-cure, making it suitable for a wide range of operating temperatures in different regions of the fuselage.  Moreover, it exhibits good tack and drape, long out life, good impact resistance, and flexible processing via autoclave, vacuum bag or press moulding.

ACG supplies MTM49 prepregs, unidirectional tapes and fabrics in several carbon and glass fibres formats to accommodate Schiebel’s specific design requirements.

ACG’s LTM212 tooling prepreg system is based upon proprietary low temperature cure epoxy based formulations that may be post-cured to produce high end use temperature tooling capable of withstanding 210°C (410°F).  At ambient temperature, LTM212 offers a maximum drape life of two and a half days and is autoclave workable for four days.  It can be cured at a minimum initial temperature of 35°C (95°F), has a shelf life of twelve months and provides a maximum Tg of 210°C (410°F) at full post-cure temperature.

LTM212 tooling can be manufactured directly from low temperature epoxy and other suitable master model materials. LTM212 offers improved tool accuracy with low residual stress, can be post-cured in an unsupported (free-standing) state, and has a low CTE matched to ACG-supplied backing structures.

ACG’s fully equipped state-of-the-art Technology Centre, built in late 2006 with funding from Umeco plc, played an active role in determining product suitability by performing a series of tests. The tests, which were carried out in accordance with Shiebel’s exacting specifications, evaluated aging, fuel resistance and overall mechanical performance.  Under the watchful eye of Mike Davies, ACG’s Test and Evaluation Manager, these ACG manufactured material specimens were subjected to tests following a prolonged (30 day) soak in ‘AVGAS’ aviation fuel heated to 40°C.  Tests were performed on two product configurations, one at standard material thickness and the other on thinner samples using standard ASTM test methods, which proved that the product was ideally suited for the intended application.

Image copyright and courtesy of Schiebel Group.

For further details contact ACG Sales Department.

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ACG’s Contract with Swift Engineering to Supply Advanced Prepreg Materials - March 2008

ACG unveils the product of a series of contracts that it secured with Swift Engineering Inc. (Swift), all of which involved the supply of a range of prepreg systems for tooling, structural and component applications.

The Killer Bee and Fire Scout Unmanned Air Vehicles (UAVs) are just two of many projects where Swift’s engineering and aerodynamic design and manufacturing expertise has been called upon to bring about the successful launch of state-of-the-art projects into the marketplace.

ACG has vast experience in this arena, having supplied a wide range of materials and technology transfer to a variety of aerospace manufacturers, including Swift Engineering, over recent years.

Swift Engineering selected ACG’s MTM®49 for the structural airframe of the low-weight, reduced drag, and combined body and wing assembly of its low-altitude, long-endurance ‘Killer Bee4 (KB4) UAVs. MTM49 series prepregs are based on 80 to 160°C (176 to 320°F) curing toughened epoxy matrix resins, and are specifically designed for component manufacture. These prepregs possess excellent ambient and hot mechanical performance combined with good impact resistance after only moderate cure cycles.

From a manufacturing standpoint, these prepregs exhibit excellent tack and drape characteristics, long out life, and flexible processing via autoclave, vacuum bag or press moulding.

The primary mission of the KB4 is intelligence gathering, but it can also be used to relay voice and data across vast distances. The Killer Bee will meet a broad range of requirements of the US Air Force, Marine Corps., Navy and the Department of Homeland Security.

MTM49 series prepregs are expertly applied in the manufacture of the combined blended-wing and fuselage structure, the profile of which reduces the overall weight and drag coefficient. It is interesting to note that both Boeing and NASA are currently exploring the design configuration of these UAVs as an option for future passenger and airfreight transportation.

KB4 has a 10ft wing span, a 12HP engine and can carry a payload up to 30lbs. It has an endurance of 15 hours with maximum payload. The deep wings and body are intrinsically stiffer than conventional UAV designs so there is no need for expensive folding mechanisms. By merging the efficient, high-lift wings and a wide airfoil-shaped body, the entire aircraft generates exceptional lift and minimizes drag, thus increasing fuel economy and, consequently, vital mission-specific flight time.

The flat design of the UAV makes it virtually invisible both to the naked eye and to radar, while also enabling several units to be stacked into a small space for storage and transport.

The KB UAV system comes complete with a trailer that can house three KB air vehicles. It also includes a pneumatic launcher operated from a ground control station, a diesel compressor and a generator. Recovery is via a net system, making the KB4 a totally runway-free system.

Currently, Swift Engineering has chosen to team with Raytheon Company - www.raytheon.com - to pursue the STUAS/Tier II competition, providing a dynamic solution to meet the Navy’s and Marine Corps’ critical requirements for a state-of-the-art small tactical unmanned aircraft system.

Swift Engineering worked closely with Northrop Grumman to develop the transformational Fire Scout vertical take-off and landing tactical MQ-8B Fire Scout UAV system, which uses a combination of ACG’s LTM®12 prepreg for tooling and MTM49 prepreg for components. This UAV will provide unprecedented situation awareness and precision targeting support for US armed forces of the future.

The Fire Scout has the ability to autonomously take off from and land on any aviation-capable warship and at prepared and unprepared landing zones in close proximity to soldiers.

ACG’s LTM12 is a low temperature, epoxy-based resin that can be post-cured to produce high temperature (200°C [392°F]) composite tooling. LTM12 tooling prepreg allows the manufacture of mould tools direct from low temperature masters, exhibits excellent tack and drape, and can be initial cured at 30°C (86°F) - with unsupported post-cure via vacuum bag or autoclave.

Powered by a turbo-shaft engine, the MQ-8B Fire Scout can reach speeds in excess of 125 knots, has an operating ceiling of 20,000ft (6.1km), a gross weight of 3,150lbs (1428kg), and approximate total flight time of 8 hours with its baseline payload and 5 hours with its target payload of 500lb.

Briefly, MTM49 series prepregs offer excellent ambient and hot mechanical performance with good impact resistance after only moderate cure cycles.

ACG and its parent company, Umeco plc, have significant interest in the aerospace market and are keen to exploit every opportunity to promote the growth potential for its materials, technology and services.

Image copyright and courtesy of Swift Engineering.

For further details contact ACG Sales Department.

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Zephyr Takes to the Skies with ACG's Composites - January 2007

With weight restrictions being a critical element in the design of Unmanned Air Vehicles (UAVs), QinetiQ’s solar and battery powered Zephyr UAV, which was designed with structural and manufacturing input from B3 Technologies Ltd., utilised ACG’s flexible project approach and received appropriate application specific materials manufactured to their own exacting specifications.

Ultra-light glass skins were combined with the ultra-high modulus carbon fibre to achieve stringent structural and weight requirements. With significant previous experience in the application of carbon composites to the manufacture of UAVs, ACG’s pre-impregnated composite materials (prepregs) were expertly applied by B3 Technologies to the manufacture of structural elements and other components, taking QinetiQ’s lightweight (sub-30kg [66lb]) 12metre wing span Zephyr to a platform record height and duration during its most recent flight trials.

Founded by John Barnard, long recognized as one of the world's most influential racing car designers, with decades of top level motor racing experience, B3 Technologies specialises in creating the finest components for high performance applications and embraces an immense understanding of the capabilities and applications of advanced composites materials

That’s exactly why QinetiQ turned to B3 Technologies and made them a subcontractor for the development of their Zephyr UAV.

Previous developments saw earlier models of the Zephyr reach a significant height. Advances in the development of the latest variant culminated in a flight time of 18 hours and an altitude of 36,000ft, with a target altitude of 50,000ft well within its reach.

Solar power was used for the ascent, reverting to batteries during dusk, which provided a further 7 hours thereafter, emphatically proving the concept. The combination of solar panels on the upper wing surface and rechargeable batteries is expected to allow Zephyr to be flown for months at a time.

The application of ACG’s carbon composites for the manufacture of single piece ‘D’ section wing spars resulted in lighter and structurally superior components, which contributed to an overall weight reduction.

One of many different parts B3 Technologies produced for the UAV, and perhaps the most impressive, is the propeller. Being extraordinarily light and almost 1 metre long, it comes out of the mould almost perfectly balanced; such is the accuracy of B3 Technologies manufacturing method applied to ACG’s prepreg materials. QinetiQ foresees a wide range of civil, defence and security applications for Zephyr, including surveillance, remote sensing, communications and atmospheric sensing. The aircraft has recently been selected as the platform for the Belgian Mercator HALE UAV system, a remote sensing demonstrator that will be used for mapping.

For further details contact ACG Sales Department.

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