Institute for Materials and Processes Prof. Conchúr Ó Brádaigh University of Edinburgh, Scotland, UK Éire Composites Teo., Galway, Ireland Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers SAMPE UK and Ireland Chapter Annual Seminar, Feb. 24 th 2017
44
Embed
Out-of-Autoclave Processing of Advanced Thermoplastic ...€¦ · ls es Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers –C. Ó
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
Prof. Conchúr Ó BrádaighUniversity of Edinburgh, Scotland, UK
Éire Composites Teo., Galway, Ireland
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel
Tanks and Launchers
SAMPE UK and Ireland Chapter Annual Seminar, Feb. 24th 2017
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
• Christopher Semprimoschnig, Simon Appel, Adriana Sirbi, ESTEC, Noordwijk, The Netherlands
• Keith Doyle, Adrian Doyle & Mike Flanagan, ÉireComposites
• Dipa Roy, University of Edinburgh
• Ioannis Manolakis, David Jones, Anthony Comer, Terry McGrail (ICOMP – Irish Composites Centre)
• David Grogan, Brendan Murray and Sean Leen, National University of Ireland, Galway
Acknowledgements
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
Personal Background / Edinburgh
• Chair of Materials Engineering, University of Edinburgh, October 2015-present
• Previously Professor at University College Cork (2014-2015) and Senior Lecturer at NUI Galway, (1990-2014)
Composites at Edinburgh
• Dr. Edward McCarthy, Lecturer (ex-U. of Manchester), started August 2016
• Dr. Dipa Roy, Lecturer (ex-ICOMP, University of Limerick), started Jan. 2017
• 5 PostDoc Researchers and 5 PhD students
• New labs being developed in testing and processing
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
ÉireComposites & CTL• 60 staff in total, including 20 engineers – only
aerospace-accredited composites manufacturing
company in Republic of Ireland
• International customer base – Bombardier, Airbus,
Aircelle, Cytec, Lotus, GKN, Siemens, FAAC,
Scotrenewables, Suzlon Energy
• CTL accredited composites materials testing
facility - over 100 customers worldwide
• Advanced R&D in thermoplastic composites and
large heated tooling
• PRI Nadcap (Composites, Testing and NDT)
• EN/AS 9100, ISO 9001 2000 & ISO 17025
Irish Composites Centre (IComp)
o IComp is an Enterprise Ireland & IDA funded
Technology Centre
o A partnership between University of Limerick, University
College Dublin, Athlone Institute of Technology and the
National University of Ireland Galway
o 21 members from Irish industry
o 3 Large Enterprises
o 18 SMEs
Current IComp Members
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
• Thermoplastics for Space - Why ?
• Automated Tape Placement Development
• Cryogenic Fuel Tanks
• Launcher Interstage Structure
• Conclusions and Future Developments
• Payload Adapter Fairing
Presentation
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
Thermoplastic Composites for Space
• Space launcher structures too large for autoclaves (Ariane 5: ø =5.4m, length over 30m)
• Possible to make large integrated TPC structures completely out-of-autoclave, using ATP and welding/joining, with close-to-autoclave properties
• CF/PEEK has good high temperature (150-180°C) and low temperature (-200°C) performance (stiffness, strength, fracture toughness)
• CF/PEEK also has good outgassing, microcracking, resistance to liquid H2 and LOX performance
• Integration of stiffeners using welding /joining/over-ATP of press-formed TPC parts
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
Thermoplastic Composites for Space
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
ESA Future Launchers (FLPP)
• Ariane 5 current space launcher (OD up to 5.4 m)
• Future Launchers Preparatory Programme (FLPP) started 2003
• Next Generation Launchers to replace Ariane 5
1. Cryogenic fuel tank – ø 500 mm demonstrator
2. Interstage structure – ø 1500 mm demonstrator
3. Payload Adapter fairing – ø 1200 mm max.
LH2
LOX
Metallic Cryo Tank
Fuel Permeability
Interstage Structure
Integration, Larger ø
Payload Adapter Fairing
More complex geometry for ATP
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
• Thermoplastics for Space - Why ?
• Automated Tape Placement Development
• Cryogenic Fuel Tanks
• Launcher Interstage Structures
• Conclusions and Future Developments
• Payload Adapter Fairing
Presentation
ATP Facility at ICOMP
AFPT tape placement machine
• Laser Heat
• Consolidation Roller
• In situ consolidation
• CF/PEEK Tape
• 12mm wide, 0.125mm thick
Fibre Optic
Cable
Material Spool
Compaction
Roller
Laser Head
Pyrometric Camera ATP Tape
Direction of travel
Compaction Roller
Tool Surface
Incoming tape
Previous
plies
CF/PEEK Tape
Material Characterisation
• Mechanical testing
• Tension, compression, flexure etc.
• Testing from +800C down to -1960C
• Conditioning/saturation of specimens
• Fibre and resin dominated tests
• Physical Testing
• Density
• Fibre volume fraction
• % crystallinity
• Outgassing – mass loss under vacuum
• LOX and LH2 testing
MECHANICAL TESTS
0° Tensile Strength
0° Tensile Modulus
0°/90° Poissons Ratio
90° Tensile Strength
90° Tensile Modulus
0° Compressive Strength
0° Compressive Modulus
90° Compressive
Strength
90° Compressive
Modulus
In-Plane Shear Strength
In-Plane Shear Modulus
Flexural Strength
Flexural Modulus
ILSS
Inspection – Micro-sections
• Micrographs of ATP and Autoclave laminates
• Autoclave laminates more consistent quality with lower void content
• Larger resin rich areas between consecutive plies in ATP
• ATP process joints visible with resin rich areas between joints
Autoclave ATP
1.1mm
1 Ply
Tape process
ply-join
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
• UD and multi-axial laminates manufactured (CF/PEEK)
• 0° flexure: 17% improvement over hot gas ATP
• 90° tensile: 58% improvement over hot gas ATP
ATP Development at ICOMP
Comparing previous hot gas ATP to laser ATP (University of Limerick, IComp and ÉireComposites)
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
DCB Panel
Lay-up [0°]30
Lay-down speed 8 m/min
Laser Power (1st ply) 1350 W
Tool Temperature 150°C
Roller Material Silicone
Roller Pressure* 1.2 Bar
Sample Type GIC Initiation
(KJ/m2)
GIC Arrest
(KJ/m2)
Autoclave 1.32 0.92
LATP 2.15 1.67
AUTOCLAVE ATP
DCB Test (Mode-I Fracture Toughness)
ATP Research – Comparison with Autoclave -(T 60% IM7/ PEEK-150) Suprem
Autoclaved laminate crystallinity c. 42%ATP laminate crystallinity c. 18%
Inst
itu
te f
or
Ma
teri
als
an
d P
roce
sses
Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh