Institute for Carbon Composites donated by
THERMOPLASTIC IN SITU FIBER PLACEMENT
Florian Henne
FOR FUTURE SOLID ROCKET MOTOR CASINGS MANUFACTURING
„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 11th - 12th 2014
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Agenda
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
Fig. 1: 2010 strap-on booster concept for Ariane 6
2500
mm
Process Evaluation6
Manufacturing of Booster Demonstrator5
Hardware Modifications4
Mechanical Properties: In Situ Consolidated Laminat es3
Parameter Optimization2
TP-AFP Process1
Summary / Outlook7
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TP-AFP Process
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
AFP - Principle
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TP-AFP Process
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
AFP - Principle
Consolidation roller
Cutting unit
Tape
Tool
Tape feedF
v
Heat source
In situ consolidated laminate
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� Minimized number of manufacturing steps� Minimized number of consumables� No reactive resin� Nearly unlimited shelf-life and production time
TP-AFP Process
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
Advantages of In Situ TP-AFP
Fig. 1: Material spool for TP-AFP
Fig. 2: In situ TP-AFP process
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� 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
T
T
F
v
F
Tape
T
TP-AFP Process
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
Challenges of In Situ TP-AFP
F: ForceT: Temperaturev: Velocity
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Automated Fiber Placement
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
TP-AFP Closed Loop Control by AFPT GmbH
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High peel resistance for all parameter sets.
Parameter optimization was not possible with wedge peel test for CF/PPS.
Parameter Optimization
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
Wedge Peel Test
Fig. 1: Wedge peel test principle [1]
[1] Hulcher B. et al. 1998, SAMPE Anaheim
Fig. 2: Test results of parameter optimization
CF/PPS wedge peel strength
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Micrographs to identify local defects� Deconsolidation (due to insufficient cooling)� Microcracks� Porosity
Density analysis to estimate the overall porosity
Parameter Optimization
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
Test methods: Micrographs and Density AnalysisDefect due to
deconsolidationCrack due to thermal
stress
1,5
1,52
1,54
1,56
1,58
Baseline 33%Placement
speed
200%Placement
speed
Processtemperature
-30°C
Processtemperature
+50°C
Den
sity
[g/c
m³]
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Mechanical Properties
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
In Situ Consolidated Laminates
Fig. 1: Tensile UD 0° test sample
0%
50%
100%
150%
200%
250%
Tensilestrength 0°
Tensilestrength 90°
Compressionstrength 0°
Compressionstrength 90°
Before processoptimization
After processoptimization
Reference (consolidated in a press)
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� Movable cutting unit:� Cut on the fly� 15.000+ cuts
� Consolidation roller:
Hardware Modifications
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
Examples: Cutting Unit and Consolidation Roller
2“
Heat source
TapeTape feed
Consolidation rollerCutting unit
Flexible silicone roller(air cooled outside)
Flexible silicone roller(conduction cooled)
Rigid metal roller(water cooled inside)
Flexible silicone roller with water cooled core
Ske
tch
Res
ult
Fig. 1: Cutting edge without and with movable cutting unit
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� Research project founded by the Bavarian Government� MT Aerospace AG, Universität Augsburg, DLR Augsburg, Technische Universität München
Manufacturing of Booster Demonstrator
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
Project ComBo
Skirt
Dome
Connection area
2500
mm
Pressure vessel
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Manufacturing of Booster Demonstrator
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
Project ComBo
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� Closed loop control compensates� Tooling geometry� Varying thermal conduction� Tape quality tolerances
Process Evaluation
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
Closed Loop Control: Nip-Point Temperature
1
2
3
Fig. 1: Sections of the pressure vessel
05001000150020002500
0100200300400500
126 136 146 156
Lase
r po
wer
[W]
Tem
pera
ture
[°C
]
Production time [s]
nip-point temperature measured by thermo camera
laser power
Dome (2)Cylinder (1) Cylinder (3)
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Process Evaluation
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
Total Productivity Improvement
Basic setup 2012 Improved setup 2014
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� 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
Summary / Outlook
09/11/2014 | Henne | Thermoplastic In Situ Fiber Placement
In Situ TP-AFP
Fig. 1: Automated manufacturing of the pressure vessel
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Technische Universität MünchenInstitute for Carbon CompositesBoltzmannstraße 1585748 Garchingwww.lcc.mw.tum.de
Contact
Address
FaxEmail
TelRoom
+49 89 /+49 89 /
Institute for Carbon Composites donated by
Dipl.-Ing. Florian Henne
289 - 103158102.03.107
289 - [email protected]
Fig. 1: Demonstrator 1 and 2 connected in burst test configuration
4.5
m