Duramold

Duramold
The Hughes H-4 Hercules, made of birch ply Duramold

Duramold is a composite material process developed by Virginius E. Clark. Birch plies are impregnated with phenolic resin, such as Haskelite and laminated together in a mould under heat (280°F) and pressure for use as a lightweight structural material.[1] Similar to plywood, Duramold and other lightweight composite materials were considered critical during periods of material shortage in World War II, replacing scarce materials like aluminum alloys and steel.[2]

The material has some advantages over metal in strength, construction technique, and weight. A cylinder made of duramold is 80% stronger than a cylinder made of aluminum.[3] There are over 17 varieties of Duramold, using various quantities of birch or poplar wood, with as many as seven plies.[4] The Duramold process has also been used to make radomes for aircraft as well as missile bodies.[5]

The Fairchild Aircraft Corporation patented the process, designing and constructing the AT-21, (NX/NC19131) as the first aircraft made using the Duramold process.[6] Several aircraft used Duramold in parts of their structure but the largest aircraft manufactured with the process is the Hughes H-4 Hercules, which was almost completely built with Duramold in very large sections. Hughes purchased rights to the process for this use.

References

  1. ^ United Service and Royal Aero Club (Great Britain), Royal Aero Club of the United Kingdom, United Service and Royal Aero Club. Flight International, Volume 42. 
  2. ^ Popular Science. Sep 1943. 
  3. ^ American Society of Naval Engineers. Journal of the American Society of Naval Engineers, inc, Volume 52. 
  4. ^ Charles Barton. Howard Hughes and his flying boat. 
  5. ^ Manufacturers Aircraft Association. Aircraft year book Aerospace Industries Association of America. 
  6. ^ Frank Woodring, Suanne Woodring. Fairchild Aircraft. 

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