Accession Number:

ADA555982

Title:

Low HAP/VOC Compliant Resins for Military Applications

Descriptive Note:

Final rept. 1 Jan 2006-1 Nov 2010

Corporate Author:

ARMY RESEARCH LAB ABERDEEN PROVING GROUND MD

Report Date:

2011-09-01

Pagination or Media Count:

979.0

Abstract:

Liquid resins used for molding composite structures are a significant source of hazardous air pollutant HAP emissions. One method of reducing styrene emissions from vinyl ester VE resins is to replace some or all of the styrene with fatty acid-based monomers. Fatty acid monomers are ideal candidates because they are inexpensive, have low volatilities, and promote global sustainability because they are derived from renewable resources. This patented technology allows for the formulation of high performance composite resins with no more than 25 wt styrene, which is a 25-50 reduction in HAP emissions vs. commercial VE resins. This work validated the commercially produced low HAP vinyl ester resins from Applied Poleramics, Inc. for use in DoD composite structures. Tests have shown that the established resin formulations met the property requirements, including viscosity, glass transition temperature, modulus, strength, short beam shear strength, and fracture toughness. Furthermore the low HAP fatty acid composites have improved weatherability relative to the baseline vinyl ester composites. The Army has demonstrated and validated the use of these HMMWV transmission container, M35A3 hood, and M939 hood under laboratory testing and field conditions. The Air Force has demonstrated the production of an F-22 canopy cover, T-38 dorsal cover, and rapid prototyping splash molds. The F-22 canopy cover and splash molds were completely validated, but the T-38 dorsal cover was only validated at the laboratory level. MCM rudders were successfully demonstrated and were demonstrated at production level and validated at the laboratory level. An economic analysis has shown that these resins will cost an additional 0.1-1.20lb depending on manufacturing scale more than baseline resins. However, these resins they reduce life cycle cost by more than 1.20lb making them economically feasible.

Subject Categories:

  • Organic Chemistry
  • Laminates and Composite Materials

Distribution Statement:

APPROVED FOR PUBLIC RELEASE