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New
York, April
18, 2006 -
EDO Corporation
(NYSE: EDO)
has manufactured
a
prototype
engine-inlet
duct using a
low-cost VaRTM
(Vacuum-assisted
Resin Transfer
Molding)
and braiding
process under
the auspices
of the Air Force
Composite
Affordability
Initiative (CAI)
program. The
CAI program
was established
to dramatically
reduce
the cost of
composite technologies
in airframe
structures.
The
advanced-design
duct features
a foreshortened,
compact geometry
with low inlet
loss.
The complicated
shape creates
manufacturing
challenges,
and the objective
of the
process
demonstration
was to achieve
required performance
and quality
with the most
affordable
manufacturing
process.
 EDO
manufactured
the compact
duct for Lockheed
Martin Aeronautics
Company, prime
contractor
of the F-35
Joint Strike
Fighter. According
to Shaw Lee,
Lockheed Martin’s
CAI
program manager, “we
looked to EDO
for a braided/VaRTM
manufacturing
approach
because unit
costs with
this process
are significantly
lower than
conventional
methods.” VaRTM
is a flight-qualified,
low-cost,
high-quality
infusion and
molding process
already used
by EDO to
produce
airframe structures
for the JASSM
missile fuselage.
Process
Braiding
was performed
over a large
mandrel,
segmented
into 35 removable
pieces to enable
removal
after
part cure.
The mandrel was
braided
with five
layers
of continuous
graphite
fiber, with local
buildups
up to eight plies
thick. Braiding
is
an automated
circular
weaving
process
that applies
tensioned
fibers
to the part surface.
EDO
used its 288-carrier
braiding
machine,
the largest of
its type
in the United
States.
This
allowed the duct
to
be produced with
the
desired fiber
coverage
without
any
gaps between
yarns.
 The
duct design
includes honeycomb
core inserts
to produce
a stiffened
duct wall. The
honeycomb
core is filled
with closed
cell foam to
assure that
resin will
not fill the
cell
walls.
Reinforcing
keel straps
were also selectively
laid up into
the duct structure.
A
high performance
epoxy resin
was then infused
into the braided
part using
the
VaRTM
process. After
the epoxy
cures,
the internal
mandrel is
removed from
the
molded
part, one
segment
at a time.
Stiffeners
are then bonded
to the duct
exterior to
reinforce
the structure
at key locations.
The
finished duct
assembly is
currently
being
pressure tested
and exposed
to
hammershock
tests that
simulate the
pressure spike
associated
with an engine
shock
wave.
About
EDO Corporation
EDO
Corporation
designs and
manufactures
a diverse
range
of products
for defense,
intelligence,
and commercial
markets, and
provides related
engineering
and
professional
services.
Major
product groups
include: Defense
Electronics,
Communications,
Aircraft Armament
Systems,
Undersea Warfare,
and Integrated
Composite
Structures.
EDO’s
advanced
systems
are at the
core of the
transformation
to lighter,
faster, and
smarter defense
capabilities.
In
2005, EDO acquired
Fiber Innovations,
Inc, a leader
in the specialty
processes of
braiding,
resin transfer
molding, and
vacuum-assisted
resin transfer
molding. Fiber
Innovations
added important
complementary
design and
manufacturing
capabilities
to
EDO’s
integrated-composite-structures
business.
With
headquarters
in New York,
EDO Corporation
(www.edocorp.com)
employs 3,000
people
worldwide.
The company
was founded
in 1925
and
had revenues
of $648
million
in 2005.
Contacts:
William
A. Walkowiak,
CFA
Director
of Investor
Relations
(212)
716-2038
ir@edocorp.com
Sara
Banda
Sr.
Corporate
Communications
Specialist
(212)
716-2071
media@edocorp.com
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