SAMPE Show Highlights Security Trends

Homeland security isn't a new topic in our world, but the panel discussion "Materials and Processes for Homeland Security" was relatively new fare at the annual International Society for the Advancement of Material and Process Engineering (SAMPE) conference, held in Long Beach on May 1 to 5. Spun M5 PIPD fiber (poly-di-imidazo-pyridinylene-phenylene) is the current "rock star" of fabric-based, composite ballistic materials, for its impact and damage-tolerance properties due to bidirectional honeycomb-like molecular structure. However, PIPD is expensive and hard to come by in quantity. Nanocomposites and advanced ceramics are under development for ballistics, but more new fiber structures and polymer advances are needed. Panel members also brought up the need for end-product maintainability as part of materials development. "Whatever we come up with in ballistic materials," commented B.A. Gama of the University of Delaware, "they must be repairable."

More extensive use of composites in primary aircraft structure has already begun (see Aviation Maintenance cover story, May 2005), and one of the processes highlighted at SAMPE--resin film infusion (RFI) as developed by GKN Aerospace for wing assemblies on the Airbus A380--doesn't require autoclave cure. That may forge a path for larger-area repairs.

Innovative tooling materials demonstrated at SAMPE accommodate faster repairs, whether in the depot or the field, as well as part prototyping. 2Phase debuted its Reconfigurable Tooling Systems, which go from liquid to solid to liquid again to produce tools that can be autoclave-cured to 350 degrees Fahrenheit and offer 1,000 pound per square inch compressive strength. Advanced Ceramics demonstrated a water-soluble material for filament winding. VARTM and Natural Process Design, through a small business innovation research phase II grant from the U.S. Air Force, have developed an experimental, self-repairing composite prepreg (vinyl ester resin and carbon fiber have been tested to date) that flows resin upon impact into delaminations between laminate layers.

Hot bonders play a key role in repair, and Heatcon reported finishing three months of environmental EMI testing to deliver the first of 20 production units to the U.S. Navy. The hardened casing can withstand sand, dust, saltwater, and explosion and also prevents radio signal disruption. Another bonder supplier, BriskHeat, displayed its Version 3.0 unit just commercialized this year, which uses a USB drive and flash card to store the last 12 runs. The company also featured its Easy Seal heating blanket.

The stricter environmental standards of the global village are answered in bromine-free one- or two-component epoxy syntactics highlighted at SAMPE by Hunstman Advanced Materials. The supplier's trademarked Epocast flame-retardant epoxies are also formulated without OBDE or PBDE.

At least 13 companies identified themselves in the official program as repair materials, services, or equipment suppliers. SAMPE reports this year's conference featured more than 200 exhibitors, 280 papers, 11 tutorials, and some 4,200 materials and process industry attendees. -- By Vicki P. McConnell

There's Nothing Trivial About This

Flashcards make learning easy and fun. Aircraft Technical Book Company has introduced Professional Pursuit flashcards for aviation maintenance technicians. Professional Pursuit is similar to the game Trivial Pursuit but instead of useless trivia, these cards contain questions and answers based on FAA tests such as the General, Airframe, and Powerplant written exams plus the FCC avionics technician's elements 1, 3, and 8 exams.

The cards were originally designed for and by Part 147 schools. The cards provide students a unique way to learn the material and prepare for written exams. For seasoned technicians, it's a fun way to refresh your knowledge. Each question is converted from the standard multiple choice (as it would appear on an FAA written exam) to a direct question- and answer-style format. Questions and answers are color-coded with questions on the front side of each card and answers on the back. They make a great portable study tool.

Professional Pursuit comes as a deck of 400 cards and costs $39.95. Aircraft Technical Book Company, 800 780-4115, www.actechbooks.com.