Hydrodynamic control surfaces are traditionally built as steel fabrications. While this gives a very strong structure, it is rather heavy and costly, it is difficult to achieve smooth surfaces, and the steel is susceptible to erosion, corrosion and marine fouling. This paper describes a conceptual design study aimed at creating a competitive advantage for the manufacturers of control surfaces by using modern materials in a composite structure. The conceptual design process, as applied here, starts by specifying the design requirements for the construction of control surfaces and listing a set of criteria against which the concept designs can be evaluated. A total of six concept designs are described and evaluated in comparison with a traditional steel fabrication, and one concept is selected for further development. This comprises a light steel frame structure with thin steel inner face plates enclosing an inner core that is filled with polyurethane foam. The surface shape is also formed with polyurethane foam poured between the face plates and a surface mold plate. Finally, the surface is sprayed with a polyurethane elastomer coating.
PRELIMINARY CONCEPTUAL DESIGN STUDY OF THE RIG5ATRON APPROACH TO FUSION POWER. APPENDICES P-T. FINAL REPORT - VOLUME I