Testing and Validation of Prototype HyVarC Layup Moldssampe.com.br/emailmkt/v_congresso_sampe/cobertura/ascentaerospace.pdf · 35 years producing layup tools to support the adoption
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
Use or disclosure of information contained herein is subject to the restrictions on the cover page.Page 1
WARNING: MATERIAL CONTAINED HEREIN IS AIP AEROSPACE PROPRIETARY INFORMATION AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, OR REPRODUCED HOWSOEVER, IN
WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DERIVATIVE WORK), OR USED FOR MANUFACTURE FOR ANYONE OTHER THAN AIP AEROSPACE WITHOUT ITS WRITTEN CONSENT, AND THAT NO
NO ITAR OR EXPORT CONTROLLED INFORMATION CONTAINED HEREIN
WARNING: MATERIAL CONTAINED HEREIN IS AIP AEROSPACE PROPRIETARY INFORMATION AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, OR REPRODUCED HOWSOEVER, IN
WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DERIVATIVE WORK), OR USED FOR MANUFACTURE FOR ANYONE OTHER THAN AIP AEROSPACE WITHOUT ITS WRITTEN CONSENT, AND THAT NO
Micrograph images: top-down view of composite working surface, white lines are microcracks
Use or disclosure of information contained herein is subject to the restrictions on the cover page.Page 11
Invar/Composite Interface Bond
Resin design and selection process tailored to Invar adhesion
– Tiered empirical testing process to select strongest bond under contour
and thermal stress
Twelve composite systems tested
– Sheet Molding Compounds (SMCs) and Prepregs
– Epoxy anhydride, benzoxazine, bismaleimide (BMI), and modified epoxy
– Different bonding and adhesion methods
Small strips
Large plates
Contoured demo tool
Fabric TypeResin Type Bond Method SMC 50K Fabric 30K Fabric 12K Fabric
SMC A A X
SMC B A X
Modified Epoxy A A X
B X
Modified Epoxy B A X X
Epoxy Anhydride A X X
B X X
Benzoxazine A X
B X
Test Plan
Invar adhesion
and thermal
cycling
Invar adhesion,
thermal cycling,
and machinability
Invar adhesion,
thermal cycling,
machinability, and
part fabrication
Use or disclosure of information contained herein is subject to the restrictions on the cover page.Page 12
Modifying Composite Working Surface
Speed and flexibility for HyVarC
repairs and changes
Minor working surface changes:
– Machine new features or slight contour changes
No additional layup necessary
New machining has no effect Invar
– New laminate plies and machining
Additional composite layers bonded to
original composite working surface
Precision machined for new surface
Example: step added and machined in demo tool
Use or disclosure of information contained herein is subject to the restrictions on the cover page.Page 13
Rebuilding Composite Working Surface
Major working surface changes: complete removal and rebuild of composite
– Composite burn-off and new surface bonded in 2-3 weeks
– Invar structure remains untouched and unchanged
Use or disclosure of information contained herein is subject to the restrictions on the cover page.Page 14
HyVarC Summary
Testing Results
Superior vacuum integrity vs. conventional composite
tooling– Part is bagged to Invar facesheet, which provides vacuum
reliability
– Held at 736mmHg for 30 minutes with 0mmHg drop after 150
thermal cycles
Robust bond interface– Invar/composite bond maintained strength throughout testing
– Extremely difficult to remove composite layer by hand
Reconfigurable / repairable surface– Composite working surface surface easily modified or repaired
with material add / subtract operations
– Base mold can be reused by burning off composite working
surface
– 2-3 week turnaround for completely new working surface
Additional Configuration Advantages
Precise dimensions with machined surface– Machined composite working surface allows precise features and
dimensional accuracy
Fast manufacturing time– Less weld hours
– No Invar machining, composite working surface machined in one step
Lower price vs. all-composite or all-Invar molds– Eliminates master model or source tool
– Reduces Invar material use (commodity by weight)
Lightweight vs. all-Invar molds– 4.76mm vs. 19mm Invar results in 50% decrease in tool weight
– Easier to handle
HyVarC is a low-cost, high-precision mold concept for
prototyping composite parts.
Use or disclosure of information contained herein is subject to the restrictions on the cover page.Page 15
WARNING: MATERIAL CONTAINED HEREIN IS AIP AEROSPACE PROPRIETARY INFORMATION AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, OR REPRODUCED HOWSOEVER, IN
WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DERIVATIVE WORK), OR USED FOR MANUFACTURE FOR ANYONE OTHER THAN AIP AEROSPACE WITHOUT ITS WRITTEN CONSENT, AND THAT NO
NO ITAR OR EXPORT CONTROLLED INFORMATION CONTAINED HEREIN
WARNING: MATERIAL CONTAINED HEREIN IS AIP AEROSPACE PROPRIETARY INFORMATION AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, OR REPRODUCED HOWSOEVER, IN
WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DERIVATIVE WORK), OR USED FOR MANUFACTURE FOR ANYONE OTHER THAN AIP AEROSPACE WITHOUT ITS WRITTEN CONSENT, AND THAT NO