Abstract: Systems and methods for manufacturing laser-perforated nanoreinforced materials are disclosed. A honeycomb core may utilize a perforated top sheet and a microperforated overlay film coupled to the perforated top sheet. The perforated top sheet and/or the microperforated film may include thermally conductive nanomaterials. The perforations in the top sheet and the microperforations in the film may be laser drilled. The nanomaterials may dissipate heat generated by the laser drilling, allowing for increased perforation speeds.

Abstract: A method of generating a pressure wave proximate an airflow surface and altering airflow to promote a localized lowering of skin friction over the airflow surface is described herein. A series of pressure waves may be configured to create a virtual riblet to control turbulent vortices in a boundary layer adjacent to the airflow surface creating a virtual riblet. The pressure waves may be configured to prevent disruption of the flow of air relative to at least one of a step or a gap associated with the airflow surface. The pressure wave generating system may be comprised of at least one of a thermoacoustic material, a piezoelectric material and a semiconductor material, and a microelectric circuit.

Abstract: A lightning strike protection material may include a fiber reinforced composite aircraft component including carbon fibers in a resin matrix. The carbon fibers may have a length greater than at least about 6 mm and include carbon nanotubes grown on the fibers, and the nanotubes may be substantially uniformly distributed on the fibers and have a length between about 1 and 100 microns. The nanotubes may decrease a surface resistance of the resin matrix.

Abstract: A lightning strike protection material may include a fiber reinforced composite aircraft component including carbon fibers in a resin matrix. The carbon fibers may have a length greater than at least about 6 mm and include carbon nanotubes grown on the fibers, and the nanotubes may be substantially uniformly distributed on the fibers and have a length between about 1 and 100 microns. The nanotubes may decrease a surface resistance of the resin matrix.

Abstract: A composite laminate for use on an external part of an aerospace vehicle has improved ultraviolet resistance and resistance to microcracking from thermal cycling. The laminate comprises a nanoreinforcement film, a support veil, and a composite layer. The laminate also can have a lightning strike protection layer and an external paint and primer. The nanoreinforcement film can comprise carbon nanomaterial and a polymer resin, and the composite layer has one or more layers of a reinforcement and a polymer resin. The carbon nanomaterial can be carbon nanofibers, and the nanoreinforcement film can have an areal weight of less than about 100 g/m2. The carbon nanomaterial can also comprise carbon nanofibers and carbon nanotubes.

Abstract: An aircraft component having an external surface includes an improved lightning strike protection surface film disposed on or proximate to the external surface. The surface film includes a preform that includes a substrate having a first areal weight density and a plurality of spaced carbon nanotubes grown on the substrate, the nanotubes having a second areal weight density. The sum of the first areal weight density and the second areal weight density is less than about 500 grams per square meter, and the preform has a surface resistance less than about 1 ohm/square.

Abstract: An aircraft component having an external surface includes an improved lightning strike protection surface film disposed on or proximate to the external surface. The surface film includes a preform that includes a substrate having a first areal weight density and a plurality of spaced carbon nanotubes grown on the substrate, the nanotubes having a second areal weight density. The sum of the first areal weight density and the second areal weight density is less than about 500 grams per square meter, and the preform has a surface resistance less than about 1 ohm/square.

Abstract: The present invention is a composite material, a process and a product formed by the process. The composite is formed by a process that includes forming a fibrous structure comprising fibers into a preform, coating the fibers of the fibrous structure preform with elemental carbon to impregnate that preform, infiltrating the preform with boron carbide to form an impregnated green body. The impregnated green body is infiltrated with liquid naphthalene or other carbon precursor, which is thereafter pyrolyzed to form a carbon char. Then, the char infiltrated green body is infiltrated with molten silicon to form a continuous matrix throughout the composite. The silicon in the continuous matrix is reacted with the carbon char to form silicon carbide.

Abstract: The present invention is a composite material, a process and a product formed by the process. The composite is formed by a process that includes forming a fibrous structure comprising fibers into a preform, coating the fibers of the fibrous structure preform with elemental carbon to impregnate that preform, infiltrating the preform with boron carbide to form an impregnated green body. The impregnated green body is infiltrated with liquid naphthalene or other carbon precursor, which is thereafter pyrolyzed to form a carbon char. Then, the char infiltrated green body is infiltrated with molten silicon to form a continuous matrix throughout the composite. The silicon in the continuous matrix is reacted with the carbon char to form silicon carbide.

Abstract: A method of forming substantially spherical ceramic beads that includes conveying an aqueous ceramic slurry to a nozzle tip that is immersed in an inert water-immiscible fluid layer. The nozzle tip is spaced a predetermined distance away from a rotating disk that is also immersed in the immiscible fluid layer. The rotating disk creates a shear force that at the nozzle tip that dislodges droplets of the aqueous ceramic slurry from the nozzle tip into the immiscible fluid layer. Once dislodged, the droplets assume a substantially spherical shape and a substantially mono-modal size distribution. The droplets are permitted to pass from the immiscible fluid layer into an aqueous gelling solution wherein the droplets are converted into rigid beads. In a preferred embodiment of the invention, the rigid beads are recovered from the gelling solution, washed, and then sintered to obtain a density of greater than about 98% of theoretical density and a sphericity of greater than about 0.95.

Abstract: A method of forming substantially spherical ceramic beads that includes conveying an aqueous ceramic slurry to a nozzle tip that is immersed in an inert water-immiscible fluid layer. The nozzle tip is spaced a predetermined distance away from a rotating disk that is also immersed in the immiscible fluid layer. The rotating disk creates a shear force that at the nozzle tip that dislodges droplets of the aqueous ceramic slurry from the nozzle tip into the immiscible fluid layer. Once dislodged, the droplets assume a substantially spherical shape and a substantially mono-modal size distribution. The droplets are permitted to pass from the immiscible fluid layer into an aqueous gelling solution wherein the droplets are converted into rigid beads. In a preferred embodiment of the invention, the rigid beads are recovered from the gelling solution, washed, and then sintered to obtain a density of greater than about 98% of theoretical density and a sphericity of greater than about 0.95.