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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 - 15097Florian.Henne@lcc.mw.tum.de

Fig. 1: Demonstrator 1 and 2 connected in burst test configuration

4.5

m