Method has been developed for fabrication of lightweight ducts that are three times stronger than aluminum ducts. Method can be used to produce either flexible or rigid ducts

Ballentine, T. J.

Bishop, R. E.

Dawn, F. S.

Roussean, C. R.

English

NASA Technical Reports Server

August 1975	 B75-10173 
NASA TECH BRIEF 
Lyndon B. Johnson Space Center
	
/ £ A 
NASA Tech Briefs announce new technology derived from the U.S. space program. They are issued to encourage 
commercial application. Tech Briefs are available on a subscription basis from the National Technical Information 
Service, Springfield, Virginia 22151. Requests for individual copies or questions relating to the Tech Brief program may 
be directed to the Technology Utilization Office, NASA, Code KT, Washington, D.C. 20546. 
Lightweight Ducts Fabricated From Reinforced Plastics and Elastomers 
Improved lightweight rigid and flexible ducts have
	 2. The duct is then cured and removed from the 
been developed that are far superior to aluminum and
	 mold. 
fiberglass ducts. Kevlar* fabrics, or equivalent,
	 The fabricated ducts are very light and durable. 
laminated with polyimide or epoxy resin are used in
	 They can withstand air or gas temperatures below 
the process for manufacturing of rigid ducts. An
	 approximately 2000 C (400° F). 
alternate approach is to use Kevlar* fabrics with 
Viton* elastomers, or equivalent, for fabrication of
	 Note: 
flexible duct. In either case the materials provide
	 Requests for further information may be directed 
two-ply ducts that weigh half as much and are three
	 to: 
times stronger than aluminum ducts. Also they will
	 Technology Utilization Officer 
withstand fatigue and abuse from impact better than 	 Johnson Space Center 
the fiberglass ducts.	 .	 Code AT3 
Houston, Texas 77058 
Rigid Ducts:	 Reference: TSP75- 10173 
Basically he fabrication involves four steps: 
1. The Kevlar* fabric is prepreged.	 Patent status: 
2. The ,fabric is then wrapped or formed on a mold
	 NASA has decided not to apply for a patent. 
and is coated with resin. 
3. The laminate is then cured, and the mold is re-
	 Source: F. S. Dawn and T. J. Ballentine 
moved.	 Johnson Space Center and 
4. The formed duct is then coated inside with ap-
	 R. E. Bishop and C. R. Rousseau of 
proximately 0.5 mm (2 mils) of Viton* and is post
	 Rockwell International Corp. 
cured,	 under contract to 
Johnson Space Center 
Flexible Ducts:
	 (MSC-19482) 
Stronger ducts can be made using Kevlar* fabrics, 
or equivalent, calendered on two sides with Viton*, or 
equivalent. These ducts can take greater abuse and 
are less permeable. The fabrication process involves 
two steps: 
1. The Viton' calender coated Kevlar* fabric is 
wrapped and formed on a mold using Viton*, or 
equivalent adhesive.
Categories: 06 (Mechanics) 
Trademark of E. I. du Pont de Nemours and	 08 (Fabrication Technology) 
Company, Wilmington, Delaware 19898. 	 04 (Materials) 
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Lightweight ducts fabricated from reinforced plastics and elastomers

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