F-15 composite engine access door

This paper presents a summary of the successfully concluded phase 1 of the two-phase Design and Manufacture of Advanced Thermoplastic Structures (DMATS) program. It addresses the design, manufacture, and validation testing of a thermoplastic F-15E forward engine access door and includes lessons learned during the concurrent product and process design development phases of the program

Process comparison study. MSFC Center Director's Discretionary Fund (CDDF)

A process comparison study was conducted using four different advanced manufacturing techniques to fabricate a composite solid rocket booster systems tunnel cover. Costs and labor hours were tracked to provide the comparison between the processes. A relative structural comparison of the components is also included. The processes utilized included filament winding, pultrusion, automated tape laying, and thermoplastic thermoforming. The hand layup technique is also compared. Of the four advanced processes evaluated, the thermoformed thermoplastic component resulted in the least total cost. The automated tape laying and filament winding techniques closely followed the thermoplastic component in terms of total cost; and, these techniques show the most promise for high quality components and lower production costs. The pultruded component, with its expensive tooling and material requirements, was by far the most expensive process evaluated, although the results obtained would not be representative of large production runs

Solvent resistant thermoplastic aromatic poly(imidesulfone) and process for preparing same

A process for preparing a thermoplastic poly(imidesulfone) is disclosed. This resulting material has thermoplastic properties which are generally associated with polysulfones but not polyimides, and solvent resistance which is generally associated with polyimides but not polysulfones. This system is processable in the 250 to 350 C range for molding, adhesive and laminating applications. This unique thermoplastic poly(imidesulfone) is obtained by incorporating an aromatic sulfone moiety into the backbone of an aromatic linear polyimide by dissolving a quantity of a 3,3',4,4'-benzophenonetetracarboxylic dianhydride (BTDA) in a solution of 3,3'-diaminodiphenylsulfone and bis(2-methoxyethyl)ether, precipitating the reactant product in water, filtering and drying the recovered poly(amide-acid sulfone) and converting it to the poly(imidesulfone) by heating

Process for preparing solvent resistant, thermoplastic aromatic poly(imidesulfone)

A process for preparing a thermoplastic poly(midesulfone) is disclosed. This resulting material has thermoplastic properties which are generally associated with polysulfones but not polyimides, and solvent resistant which is generally associated with polyimides but not polysulfones. This system is processable in the 250 to 350 C range for molding, adhesive and laminating applications. This unique thermoplastic poly(imidesulfone) is obtained by incorporating an aromatic sulfone moiety into the backbone of an aromatic linear polyimide by dissolving a quantity of a 3,3',4,4'-benzophenonetetracarboxylic dianhydride (BTDA) in a solution of 3,3'-diaminodiphenylsulfone and bis(2-methoxyethyl)ether, precipitating the reactant product in water, filtering and drying the recovered poly(amide-acid sulfone) and converting it to the poly(imidesulfone) by heating

Development of a beam builder for automatic fabrication of large composite space structures

The composite material beam builder which will produce triangular beams from pre-consolidated graphite/glass/thermoplastic composite material through automated mechanical processes is presented, side member storage, feed and positioning, ultrasonic welding, and beam cutoff are formed. Each process lends itself to modular subsystem development. Initial development is concentrated on the key processes for roll forming and ultrasonic welding composite thermoplastic materials. The construction and test of an experimental roll forming machine and ultrasonic welding process control techniques are described

Complex stamp forming of advanced thermoplastic composites

The inherent advantages of thermoplastics over the traditional thermoset composite systems are well recognized in the aeronautics community. The main advantages are the much faster processing and the higher toughness. The current advanced thermoplastic material systems provide excellent mechanical performance but their main disadvantage is the difficult processing. Ideally, future aircraft subcomponents with complex shapes can be readily formed on the basis of pre-consolidated tailored laminates based on uni-directional plies. However, to exploit the full potential of thermoplastic composites models are to be developed in order to predict the process feasibility and product performance in an early stage of development. This paper addresses a number of steps to increase the accuracy of stamp forming simulations and highlights promising results for identifying intra-ply shear and tool-ply behavior of thermoplastic composites. A comparison of the forming behavior of a doubly curved reference part with simulations will be presented. The paper concludes with remarks on necessary future researc

Interfaces and interfacial effects in glass reinforced thermoplastics - Keynote Presentation

Optimization of the fibre-matrix interphase region is critical to achieving the required performance level in thermoplastic matrix composites. Due to its initial location on the fibre surface, the sizing layer is an important component in the formation and properties of the composite interphase. Consequently, any attempt to understand the science of the composite interphase must encompass an understanding of the science of sizing. In this paper the role of sizings from fibre manufacture through to performance of composite parts is reviewed. In particular the role of organosilane coupling agents and how the formation of a polysiloxane interphase is influenced by the surface properties of the fibre is examined. The influence of the sizing film former in terms of its level of interaction with the silane coupling agent is also examined. The importance of residual stresses in thermoplastic composites in the values obtained for the apparent adhesion levels in these systems is highlighted. These residual stresses are shown to play a significant role in determining the level of interfacial strength in thermoplastic composites and in particular in polyolefin matrices. By applying some of the available models for this phenomenon this analysis is extended to explore the effect of the anisotropic fibre microstructure of carbon, aramid and natural fibres on the apparent interfacial strength in thermoplastic composites

Feasibility study of fusion bonding for carbon fabric reinforced Polyphenylene Sulphide by hot-tool welding

In recent years, there is a growing interest in joining techniques for thermoplastic composites as an alternative to adhesive bonding. In this article, a fusion bonding process called hot-tool welding is investigated for this purpose and the used material is a carbon fabric reinforced polyphenylene sulphide. The welds are first observed through a microscope, after which the quality is experimentally assessed using a short three-point bending setup. A comparison is made between the welded specimens and the equivalent hot pressed specimens. It can be concluded that the hot-tool welding process is very promising for the welding of material under study and that the short three-point bending setup proves interesting for evaluating bonds between composite specimens

Physical modelling of amorphous thermoplastic polymer and numerical simulation of micro hot embossing process

Micro hot embossing process is considered as one of the most promising micro replication processes for manufacturing of polymeric components, especially for the high aspect ratio components and large surface structural components. A large number of hot embossing experimental results have been published, the material modelling and processes simulation to improve the quality of micro replication by hot embossing process are still lacking. This paper consists to 3D modelling of micro hot embossing process with amorphous thermoplastic polymers, including the mechanical characterisation of polymers properties, identification of the viscoelastic behaviour law of the polymers, numerical simulation and experimental investigation of micro hot embossing process. Static compression creep tests have been carried out to investigate the selected polymers’ viscoelastic properties. The Generalized Maxwell model has been proposed to describe the relaxation modulus of the polymers and good agreement has been observed. The numerical simulation of the hot embossing process in 3D has been achieved by taking into account the viscoelastic behaviour of the polymers. The microfluidic devices with the thickness of 2 mm have been elaborated by hot embossing process. The hot embossing process has been carried out using horizontal injection/compression moulding equipment, especially developed for this study. A complete compression mould tool, equipped with the heating system, the cooling system, the ejection system and the vacuum system, has been designed and elaborated in our research. Polymer-based microfluidic devices have been successfully replicated by the hot embossing process using the compression system developed. Proper agreement between the numerical simulation and the experimental elaboration has been observed. It shows strong possibility for the development of the 3D numerical model to optimize the micro hot embossing process in the future