The problem — Damage Resistance Using Resin Infusion Processes

• Producing damage-resistant composite parts using resin infusion processes has long been a problem for composite engineers. Most resin infusion systems are inherently brittle, and the viscosity levels necessary to achieve the injection process preclude the use of toughening agents. Attempts to introduce toughness into the process (films, binders, etc.,) have proven expensive, time consuming and ineffective.

PRIFORM — The Solution

• Now, Cytec Engineered Materials has devised a revolutionary new system of materials that solve the problem. Called PRIFORM, the system consists of a fine line of toughening fiber woven into the preform (instead of attempting to put the toughening agent into the resin), and then processed exclusively with Cytec’s 977-20 resin-infusion resin.
• When the low-viscosity matrix resin is introduced into the mould, the toughener dissolves into the matrix distributing its toughening characteristics throughout the part. The result is a revolutionary breakthrough in the field of toughened resin infusion manufacturing.

PRIFORM Means Confidence

• PRIFORM materials negate the problems associated with other methods that are used to introduce toughening agents. It opens the door to the use of resin infusion processes for many part applications.
• And best of all, the properties of composite structures manufactured this way are comparable to the toughened prepreg systems that have been used successfully on damage-resistant parts for many years.

PRIFORM Materials Offer Additional Benefits

• Currently carbon and glass fibers in preforms and non-crimp fabrics are stitched using insoluble polyester fibers. This causes residual stresses in the final cured component, creates potential moisture absorption points and causes difficulties in discriminating between stitches and defects in non-destructive testing processes.
• With PRIFORM, the stitches dissolve before the resin gel point, thus eliminating problems caused by the polyester fiber.

• The potential for PRIFORM is limitless. PRIFORM will allow composite parts to be used in areas of the aircraft that were previously out of reach for conventional resin infusion processes and prepreg composites.

Applications and Performance
	Better Performance Excellent structural performance with an extensive aerospace qualification database of applications and experience Light weight, damage-resistant parts requiring fewer fasteners and assembly steps Superior flame, smoke and toxicity properties for interior applications An opportunity to significantly lower manufacturing/assembly costs

From wing spars to helicopter blades and metal fittings, resin infused components are now a design option for more areas of an aircraft — with all the weight-saving and cost benefits that advanced composite materials offer. Modern military and commercial aircraft are already using up to 25% composites by weight. With this new toughened resin infusion system, the percentage will inevitably go skyward.