Engineered Low Density Buoyancy Foams for Deep Submersibles

Deep submersibles that reach the deepest part of the ocean, such as the Human Occupied Deep Submersible Vehicle Alvin (Alvin), rely on syntactic buoyancy foam to return to the surface. Alvin is currently capable of reaching depths of up to 4500 meters, which allows for the exploration of approximately two-thirds of the ocean floor. However, an ongoing upgrade to Alvin will allow for depths of 6500 meters and open up 99 percent of the ocean floor for a new era of scientific exploration. New lightweight syntactic buoyancy foam capable of man-rating to 6500 meters is required, but does not currently exist. In response, the U.S. Navy is currently seeking new syntactic foams with densities of 30 +2/-1 pcf that are capable of man-rating to 6500 meters. Composite Technology Development (CTD), working with strategic partners Trelleborg Offshore (Trelleborg) and Alion Science and Technology (Alion), proposes to deliver revolutionary syntactic buoyancy foam through incorporation of previously unachievable loading levels of nano-particle reinforcement. Leveraging currently ongoing efforts to develop ultra-highly loaded carbon nanotube polymer composites, the new syntactic buoyancy foam will be enabled through a unique material processing and manufacturing technique.