• Multiple hit capability at the same impact point within 1 square inch.
• Able to carry structural load
• Improved flame resistance
• Lightweight
• Moisture resistance
• Chemical resistance
• High temperature stability
• Manufacturing process is environmentally friendly

Applications

• SAPI
• Man-portable shields
• Shipping containers
• Vehicles and properties protection
• Shelters

Microcellular Carbon Graphite Foams and Carbon Composites

Microcellular carbon graphitic foam is a new foamed material which contains open-celled microcellular/carbon graphitic network created from carbon fiber precursors. Our foaming process aligns the graphene planes along each ligament axis. The morphology of the ligaments resembles that of carbon fibers, and hence, their mechanical characteristics are similar to those of the fibers’. The foams can be used as net shaped preforms for reinforcement of structural composites, sandwich core, and structural components for high temperature applications.

Microcellular carbon/carbon composites are carbon fibers reinforced carbon matrix that have a microcellular morphology. The fibers can be chopped, unidirectional or woven. Wright Materials Research Co. (WMR) has developed two proprietary foaming and post processing technique for this class of ultra-lightweight carbon material.

• Single Step Process
• Environmentally friendly
• Scalable to very large parts
• Physical and functional properties of parts can be tailored by WMR's processing technique
• Foam density can be controlled from a few pcf to over 70 pcf
• Starting materials include isotrophic pitch, mesophase pitch, PAN, and various polymers
• WMR's agile foaming technique offers customization
• Modulus of carbon foams as high as 366 ksi, compressive strength 4200 psi, fracture strain 42% for 31 pcf (.49 g/cc) foam
• 13 pcf foam has 400 psi compressive strength and fracture strain over 67%
• Near zero CTE, no out-gassing, superior performance- to-weight ratio, high temperature stability
• Chemical inertness
• Excellent fracture toughness
• Graphitic foam has over 78% compression strain
• Conductivity can be tailored from low to high
• WMR’s C/graphitic & C/C foams offer superior mechanical properties that are ideal for load carrying applications in severe environments
  

Liquid Crystalline Polymer Foams WMR Exclusive

Wright Materials Research Co. has developed a single-step, environmentally friendly foaming technique that transforms advanced resins into high-temperature microcellular foams with superior thermo-mechanical properties.

• very high fracture strain/fracture toughness (does not fail even at 85-90% strain)
• very high strength (compression loading of up to 64 ksi shows no fracture)
• high temperature capabilities (useful temperature is over 450° F)
• machinable (can be sawed, cut threaded, sanded, or ground)
• low rate of thermal expansion (.0002-.0004 in/in °F in flow direction)
• controllable pore size (from, e.g., a few microns to a few mm)
• easily bonded to other components (including metals)
• very smooth surface after grinding or polishing
• moisture absorbance < 0.1%
• low mold shrinkage
• solvent resistant
• fire retardant
• save over 50% in material cost and weight
• processing technique (non-solvent) is environmentally friendly
• short processing time (4 hours as compared to weeks)
• thermoplastic makes it recyclable

Nano and Transparent Foams WMR Exclusive

• Aircraft Canopies
• Windscreens
• Windows for commercial aircraft
• Space structures
• Sensor covers
• Lenses
• Ground Structures
• Trucks, Buses, Trains, Surface vehicles
• Ships, Boats
• Other vehicles
• Ballistic resistant windows
• Viewing windows for ovens

Metalized Thin Films WMR Exclusive

Wright Materials Research Co. (WMR) has developed a processing method for preparing metallized polymer thin films and structures.  A thin metal layer was formed on the surfaces of polymer thin films or structures by an in situ chemical process. The polymer substrate and the thin metal layer has excellent bonding strength without the use of an adhesive.  We have demonstrated our invention for preparing various metallized polymer thin films and sheets including poly (arylene ether), polyamide, polyimide, polyester, and polyolefin thin film, as well as their copolymer, blend, and composite thin films.  We can tailor the thermal-mechanical and electrical properties of the metallized polymer thin films and structures via our nano-composite technology.  Conventional metallized polymer thin films either were fabricated by sputtering or bonding techniques.  Comparing to the conventional metallized polymer thin films our products have the following features:

• robust mechanical properties
• higher temperature stability
• Eliminates the bonding and interface problems between the coating and the base material
• Eliminates the internal stresses in the film due to the coating process
• Eliminates the need for expensive coating or sputtering equipment

Reconfigurable Tooling Process Improvements

• Advanced aircraft composite structures
• Composite spars and ribs
• Automobile components
• Beams for bridges and buildings
• Hat-shaped structures with internal reinforcements
• Hollow turbine blades
• Hollow tubes and structures
• Surface vehicle components
• Military aircraft components
• Cargo components
• Constructions
• Space structures
• Missile components
• Aeropropulsion structures

Wright Materials Research Technical Capabilities

• Process advanced microcellular polymer & carbon foams for aircraft & aerospace sandwich structures
• Process supermicrocellular and nanocellular high Tg polymer foams for canopies & windscreen applications
• Prepare reflective  & conductive polymer thin films (via in-situ metallization) & space mirrors
• Process polymer nanofibers
• Develop reconfigurable tooling techniques for rapid composite prototyping and low cost fabrication of composite structures
• Process reconfigurable mandrel materials for composite manufacturing
• Develop innovative fabrication methods for advanced composites
• Fabricate composite structures (aerospace, ground transportation and infrastructure, etc.) using a resin transfer molding (RTM) technique
• Process advanced polymers, liquid crystalline polymers and  their blends, and transparent polymers
• Process lightweight sandwich materials & structures for ballistic and blast protections
• Develop SMP foams & sandwich materials
• Fabricate filter media to remove very - ultra-fine particles