Implementation of In-Process Inspection for Consolidating Hybrid Organosheets for Optimized Thermopl
Abstract
ONR Program Manager: Dr. Anisur Rahman - Airframe Structures and Materials (Code 35) - High-performance reinforced thermoplastic sys,tems are being researched in order to use them in primary and secondary structural applications. In addition to impact, chemical, an,d flame resistance, thermoplastic material systems offer several attractive benefits for aircraft structural applications because of, their resistance to aggressive environments such as high humidity, high temperature, and saltwater exposure as well as less stringe,nt cleanroom requirements and no shelf life. Because of these advantages, reinforced thermoplastics (RTP) are now being considered,for key aircraft structural applications and integration into automated manufacturing. Although the cycle time for thermoplastic is, considerably short compared to the cure time of thermoset materials, improvements must be made on the preparation of organosheets,,which are the pre-consolidated multi-layer fully impregnated sheets or blanks. The organosheets can be either a single material syst,em or a hybrid system optimized for the structural application. The organosheets are used for thermoforming applications such as com,pression-molding. In order to develop lightweight structures that are capable of sustaining multi-axial loads, often, parts are enha,nced with overmolding process, where injection molding of chopped fibers following compression molding of continuous fiber primary l,oad-bearing member(s). This hybrid process enables the implementation of complex part designs that were not possible with just compr,ession molding and short cycle time with chopped fiber injection while allowing the benefits of high structural strength from contin,uous fiber thermoplastic systems. In addition, this hybrid process can be fully automated for improving manufacturing rates and cons,istency while reducing the overall cost. In order to increase the accuracy of the placement of composite plies, an optical in-proces,s inspection systemis utilized. This is integrated with a heated consolidation press in order to produce the organosheets with local,ized reinforcement areas for design requirements. Due to this capability, non-traditional joining approaches such as fusion bonding,(welding) and overmolding can be implemented in order to significantly reduce weight and cost over mechanical fastening and adhesive, bonding. The automotive industry has successfully used thermoplastics in high-rate applications. Although the rates are not as dema,nding as automotive, the advanced air mobility and aircraft industry require significant improvements to part quality and consistenc,y to relate part performance to design data. The primary goal of this research program is to optimize organosheet production process, for overmolding of lightweight structures. This abstract is publicly releasable.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Jul 13, 2022
- Source ID
- N000142212610
Entities
People
- Waruna Seneviratne
Organizations
- Office of Naval Research
- United States Navy
- Wichita State University