THERMOPLASTIC IN SITU FIBER PLACEMENT

Transcription

1 THERMOPLASTIC IN SITU FIBER PLACEMENT FOR FUTURE SOLID ROCKET MOTOR CASINGS MANUFACTURING Florian Henne A Comprehensive Approach to Carbon Composites Technology Symposium on the occasion of the 5 th anniversary of the Institute for Carbon Composites Research Campus Garching, September 11 th - 12 th 2014 Institute for Carbon Composites donated by

2 Agenda TP-AFP Process Parameter Optimization Mechanical Properties: In Situ Consolidated Laminates Hardware Modifications Manufacturing of Booster Demonstrator Process Evaluation 2500 mm 7 Summary / Outlook Fig. 1: 2010 strap-on booster concept for Ariane 6 2

3 TP-AFP Process AFP - Principle 3

4 TP-AFP Process AFP - Principle v Cutting unit Consolidation roller F Tape Tape feed Heat source In situ consolidated laminate Tool 4

5 TP-AFP Process Advantages of In Situ TP-AFP Minimized number of manufacturing steps Minimized number of consumables No reactive resin Nearly unlimited shelf-life and production time Fig. 1: Material spool for TP-AFP Fig. 2: In situ TP-AFP process 5

6 TP-AFP Process Challenges of In Situ TP-AFP Complex process with a multitude of influencing factors Sensitive to placement head orientation High quality raw material Very accurate temperature adjustment for in situ consolidation F v F Tape T T T F: Force T: Temperature v: Velocity 6

7 Automated Fiber Placement TP-AFP Closed Loop Control by AFPT GmbH 7

8 Parameter Optimization Wedge Peel Test CF/PPS wedge peel strength Fig. 1: Wedge peel test principle [1] Fig. 2: Test results of parameter optimization High peel resistance for all parameter sets. Parameter optimization was not possible with wedge peel test for CF/PPS. [1] Hulcher B. et al. 1998, SAMPE Anaheim 8

9 Parameter Optimization Test methods: Micrographs and Density Analysis Micrographs to identify local defects Deconsolidation (due to insufficient cooling) Microcracks Porosity Defect due to deconsolidation Crack due to thermal stress Density analysis to estimate the overall porosity Density [g/cm³] 1,58 1,56 1,54 1,52 1,5 Baseline 33% Placement speed 200% Placement speed Process temperature -30 C Process temperature +50 C 9

10 Mechanical Properties In Situ Consolidated Laminates 250% 200% 150% Fig. 1: Tensile UD 0 test sample 100% Reference (consolidated in a press) 50% Before process optimization 0% Tensile strength 0 Tensile strength 90 Compression strength 0 Compression strength 90 After process optimization 10

11 Hardware Modifications Examples: Cutting Unit and Consolidation Roller Movable cutting unit: Cut on the fly cuts Consolidation roller Cutting unit Tape Tape feed Heat source 2 Fig. 1: Cutting edge without and with movable cutting unit Consolidation roller: Flexible silicone roller (air cooled outside) Flexible silicone roller (conduction cooled) Rigid metal roller (water cooled inside) Flexible silicone roller with water cooled core Result Sketch 11

12 Manufacturing of Booster Demonstrator Project ComBo Research project founded by the Bavarian Government MT Aerospace AG, Universität Augsburg, DLR Augsburg, Technische Universität München Skirt Dome 2500 mm Pressure vessel Connection area 12

13 Manufacturing of Booster Demonstrator Project ComBo 13

14 Process Evaluation Closed Loop Control: Nip-Point Temperature nip-point temperature measured by thermo camera Temperature [ C] laser power Cylinder (1) Dome (2) Cylinder (3) Production time [s] Laser power [W] Fig. 1: Sections of the pressure vessel Closed loop control compensates Tooling geometry Varying thermal conduction Tape quality tolerances 14

15 Process Evaluation Total Productivity Improvement Basic setup 2012 Improved setup

16 Summary / Outlook In Situ TP-AFP Density analysis and micrographs were effective for optimization High mechanical properties Stable process upscaled from coupon level to aerospace part In situ consolidation was achieved for full size demonstrator Burst test: October 2014 Research Topics: - Online quality assurance - In situ metal-cfrp hybrid structures - Higher part complexity - Process simulation Fig. 1: Automated manufacturing of the pressure vessel 16

17 Contact Dipl.-Ing. Florian Henne Room Tel Fax / / Florian.Henne@lcc.mw.tum.de 4.5 m Address Technische Universität München Institute for Carbon Composites Boltzmannstraße Garching Fig. 1: Demonstrator 1 and 2 connected in burst test configuration Institute for Carbon Composites donated by 17