Fabrication of a Prototype Composite F/A-18C/D Generator Housing

An advanced composite housing for the F/A-18C/D Generator Converter Unit (GCU) has been developed. The composite housing directly replaces the existing aluminum housing, and provides lighter weight and improved thermal performance. The composite housing uses IM7/954-2A material, with embedded aluminum pin fins in selected areas for thermal management. A fabrication procedure for the composite housing was developed, using matched metal compression molding, with adhesive bonding of secondary components. Two prototype housings were fabricated and will be tested for qualification.