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COMPARISON OF PROPERTIES OFOUT-OF-AUTOCLAVE LAMINATES MADE BY
AUTOMATED FIBER PLACEMENT PROCESS AND HAND LAY-UP PROCESS
Kulbir Singh MadhokConcordia Centre for Composites (CONCOM)
Mechanical and Industrial Engineering Department, Concordia University
http://concom.encs.concordia.ca/
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CONTENTS• OOA Prepreg Technology• Automated Manufacturing• Manufacturing and Testing of Samples• Challenges• Quality Assurance• Mechanical Test Results• Microscopic Analysis• Cost Model• Conclusion
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• OOA Prepreg Technology• Automated Manufacturing• Manufacturing and Testing of Samples• Challenges• Quality Assurance• Mechanical Test Results• Microscopic Analysis• Cost Model• Conclusion
4
OOA Prepreg Technology• Prepregs designed specifically for processing without
the autoclave• Dates back to 1990’s• Used only for Secondary and Non-Structural Parts• Today, for Primary/Secondary Aerospace Structures• Airbus A350 XWB Secondary Wing Panel Sets, 2013• Automotive body, Racing, Marine, Infrastructure• Newer OOA prepreg systems has been aided by a
better– Understanding of mechanisms of air extraction– Tailoring resin rheology
% Voids Content !!!RESIN RICH AREAS !!!
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Advantages of OOA Technology
• Potential processing cost reduction– Autoclaves are expensive equipment capital– Less expensive tooling material (OOA typically
low-moderate cure temperature)– Energy savings
• Increased Production / Low Cycle-time• Reduced Overheads• Large sized structures manufacturing can be
facilitated• Sandwich panels can be cured more easily• Larger manufacturer and subcontractor base
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OOA Technology ProcessingFully impregnated
UD Tape
Proper de-bulking removes the entrapped air
Air entrapment between plies
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• OOA Prepreg Technology
• Automated Manufacturing• Manufacturing and Testing of Samples• Challenges• Quality Assurance• Mechanical Test Results• Microscopic Analysis• Cost Model• Conclusion
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Automated Manufacturing• Automated Tape Laying
– Single wide UD tape (6’’ to 12’’)– Flat or Gentle Contour parts– High Lay-up rate
• Automated Fiber Placement– Single or Multiple tape (0.25’’ to
0.5’’)– Smaller parts with Complex
Geometries– Debulking achieved by Roller
Pressure
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Automated ManufacturingMaterials Options• Resins: Any, e.g. epoxy, polyester, vinylester, phenolic• Fibers: Any. But must be provided in the form of a uni-directional tape; with a
width of 0.125-0.5 inch or 6-12 inches• Cores: Can be used; but must be able to take the load applied by the robotic
arm while laying the fibers
Main Advantages• This can be a very fast and therefore economic method of laying material
down• Out of Autoclave Manufacturing• Can be used to make typical parts that are required in large numbers• Minimal labour required• Automated process, hence precision and accuracy
Typical Applications• Primarily to make Fuselage, Tail-booms, Flat plates, Aircraft Wings• In Aerospace and Automobile industry its used to make wide variety of parts
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Prepreg and Tool Preparation
Ply CollationVacuum Bagging
Curing NDE/NDTMachining and
Assembly
Hand Lay-up• Ply Cutting
• Layup
• Debulking
• Inspection
AFP
• Layup
• Inspection· Curing (Pressure)· Out-of-Autoclave (No pressure)
Sequence of Operations in AFP and HLU Processes
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• OOA Prepreg Technology• Automated Manufacturing
• Manufacturing and Testing of Samples
• Challenges• Quality Assurance• Mechanical Test Results• Microscopic Analysis• Cost Model• Conclusion
12
Present Work
• Investigate and compare the properties of OOA laminates made by AFP and Hand Lay up– Tensile– Compressive– In-Plane Shear
• Evaluate the effect of pressure in the curing process• Microscopic analysis• Demonstrate Cost model• Future Work
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Manufacturing and Testing of Samples
ASTM Test
Method
Measured Property
Laminate Length /
Width (mm)
Coupon Length /
Width (mm)
Stacking Sequence
D3039Tensile
Modulus and Strength (0°)
304.8/304.8 254/12.7 [0]8
D3039Tensile
Modulus and Strength (90°)
228.6/304.8 177.8/25.4 [90]16
D3518In-Plane Shear Modulus and
Strength304.8/304.8 254/25.4
[+45/-45]10s
D3410Compressive Modulus and Strength (0°)
190.5/304.8 139.7/12.7 [0]12
AFP + Autoclave
AFP + OOA(No Pressure)
HLU + Autoclave
HLU + OOA(No Pressure)
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• OOA Prepreg Technology• Automated Manufacturing• Manufacturing and Testing of Samples
• Challenges• Quality Assurance• Mechanical Test Results• Microscopic Analysis• Cost Model• Conclusion
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Challenges
• Quality Assurance– To achieve internal void content as low as Autoclave
Cured Materials (<1%)– Minimize Resin Rich areas– Ensure High Fiber Volume Fraction (~55%)
• Maintain Structural Performance– Tensile, Shear, Compressive
• Flexible curing with various manufacturing techniques– HLU, AFP, ATL or Combination
• Cost effectiveness of the process (AFP+OOA)
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Quality Assurance
• OOA processing requires inherently more process control and greater manufacturing controls over lay-up, debulking, cure and inspection to ensure good part quality with low void contents– Dual-loop temperature control in the Autoclave/Oven– DSC test of the specimens to ensure proper Degree of
Cure– Microscopy to evaluate the Void Content, the Fiber
Volume and the Resin Rich Areas• Proper processing is key to OOA prepreg laminate quality• Proper Vacuum Pressure must be maintained all times
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0 50 100 150 200 250 3000
20
40
60
80
100
120
140
Oven Temperature
Part Temperature
Time (Minutes)
Tem
per
atu
re (
Deg
C)
Curing Cycle
Free Standing Post-cure at 177 °C for 2 hours
2.5ºC/minramp
Pressure 60 psi
(Optional)
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• OOA Prepreg Technology• Automated Manufacturing• Manufacturing and Testing of Samples• Challenges• Quality Assurance
• Mechanical Test Results• Microscopic Analysis• Cost Model• Conclusion
19
0º Tensile Test
149 GPa
140 GPa
157 GPa
167 GPa
20
90º Tensile Test
10 GPa
9 GPa
10 GPa
11 GPa
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Shear Test Results
-0.01 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.080
10
20
30
40
50
60
70
80
90
Shear Test
Strain
Str
es
s (
Mp
a)
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In-Plane Shear Test
5 GPa
4.5 GPa
5.3 GPa
5.8 GPa
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Summary of Test Results
Manufacturing Combination
Tensile Modulus and Strength (0°)
Tensile Modulus and Strength (90°)
In-Plane Shear Modulus and
Strength
Compressive Modulus and Strength (0°)
HLU+OOA140 Gpa
1700 Mpa
9 Gpa
37 Mpa
4.5 Gpa
72 Mpa
104 Gpa
1223 Mpa
HLU+AC149 Gpa
1755 Mpa
10 Gpa
43 Mpa
5 Gpa
79 Mpa
115 Gpa
1253 Mpa
AFP+OOA157 Gpa
1785 Mpa
10 Gpa
46 Mpa
5.3 Gpa
82 Mpa
113 Gpa
1248 Mpa
AFP+AC167 Gpa
1829 Mpa
11 Gpa
49 Mpa
5.8 Gpa
85 Mpa
125 Gpa
1276 Mpa
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Summary of Test Results
Manufacturing Combination
Tensile Modulus and Strength (0°)
Tensile Modulus and Strength (90°)
In-Plane Shear Modulus and
Strength
Compressive Modulus and Strength (0°)
HLU+OOA140 Gpa
1700 Mpa
9 Gpa
37 Mpa
4.5 Gpa
72 Mpa
104 Gpa
1223 Mpa
HLU+AC149 Gpa
1755 Mpa
10 Gpa
43 Mpa
5 Gpa
79 Mpa
115 Gpa
1253 Mpa
AFP+OOA157 Gpa
1785 Mpa
10 Gpa
46 Mpa
5.3 Gpa
82 Mpa
113 Gpa
1248 Mpa
AFP+AC167 Gpa
1829 Mpa
11 Gpa
49 Mpa
5.8 Gpa
85 Mpa
125 Gpa
1276 Mpa
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Summary of Test Results
Manufacturing Combination
Tensile Modulus and Strength (0°)
Tensile Modulus and Strength (90°)
In-Plane Shear Modulus and
Strength
Compressive Modulus and Strength (0°)
HLU+OOA140 Gpa
1700 Mpa
9 Gpa
37 Mpa
4.5 Gpa
72 Mpa
104 Gpa
1223 Mpa
HLU+AC149 Gpa
1755 Mpa
10 Gpa
43 Mpa
5 Gpa
79 Mpa
115 Gpa
1253 Mpa
AFP+OOA157 Gpa
1785 Mpa
10 Gpa
46 Mpa
5.3 Gpa
82 Mpa
113 Gpa
1248 Mpa
AFP+AC167 Gpa
1829 Mpa
11 Gpa
49 Mpa
5.8 Gpa
85 Mpa
125 Gpa
1276 Mpa
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Summary of Test Results
Manufacturing Combination
Tensile Modulus and Strength (0°)
Tensile Modulus and Strength (90°)
In-Plane Shear Modulus and
Strength
Compressive Modulus and Strength (0°)
HLU+OOA140 Gpa
1700 Mpa
9 Gpa
37 Mpa
4.5 Gpa
72 Mpa
104 Gpa
1223 Mpa
HLU+AC149 Gpa
1755 Mpa
10 Gpa
43 Mpa
5 Gpa
79 Mpa
115 Gpa
1253 Mpa
AFP+OOA157 Gpa
1785 Mpa
10 Gpa
46 Mpa
5.3 Gpa
82 Mpa
113 Gpa
1248 Mpa
AFP+AC167 Gpa
1829 Mpa
11 Gpa
49 Mpa
5.8 Gpa
85 Mpa
125 Gpa
1276 Mpa
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• OOA Prepreg Technology• Automated Manufacturing• Manufacturing and Testing of Samples• Challenges• Quality Assurance• Mechanical Test Results
• Microscopic Analysis• Cost Model• Conclusion
28
Microscopy- Resin Rich Areas
Hand Lay-up
AFP
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Hand Lay-up with Autoclave
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AFP + OOA (No Pressure)
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6.7µm
7.7µm
6.9µm
7.2µmHLU
AFP
Autoclave Cured Oven Cured
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• OOA Prepreg Technology• Automated Manufacturing• Manufacturing and Testing of Samples• Challenges• Quality Assurance• Mechanical Test Results• Microscopic Analysis
• Cost Model• Conclusion
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• The cost of prepreg tape, $80/lb• The weight of the prepreg needed 6 lbs• Skilled Labor / Technician cost, $75/hr• Mold cost $10,000 (Low Cost) and $30,000 (e.g. Invar Steel)• AFP Layup rate of 3lb/hr• Autoclave/Oven cycle time 6 hours• Oven cue time 3 hours• Over-head cost of Autoclave, $180• Over-head cost of AFP Machine, $250/hr• Over-head cost of Oven $60/hr• Inspection Costs $250/hr• Inspection time 1 hour• Miscellaneous costs $100
Cost Model Assumptions
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Prepreg Labour / Technician
Cost of Tooling
AFP Over-head
Autoclave Overhead
Oven Overhead
Inspection Cost
Misc
AFP + AC 528 300 360 500 1080 180 250 100
AFP + OOA 528 225 120 500 0 540 250 100
HLU + AC 528 1050 360 0 1080 180 250 100
HLU + OOA 528 975 120 0 0 540 250 100
$100
$300
$500
$700
$900
$1,100 Cost Comparison
Co
st (C
AD
)
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Prepreg Labour / Technician
Cost of Tooling
AFP Over-head
Autoclave Overhead
Oven Overhead
Inspection Cost
Misc
AFP + AC 528 300 360 500 1080 180 250 100
AFP + OOA 528 225 120 500 0 540 250 100
HLU + AC 528 1050 360 0 1080 180 250 100
HLU + OOA 528 975 120 0 0 540 250 100
$100
$300
$500
$700
$900
$1,100 Cost Comparison
Co
st (C
AD
)
$3,298 $2,263 $3,548 $2,513
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• OOA Prepreg Technology• Automated Manufacturing• Manufacturing and Testing of Samples• Challenges• Quality Assurance• Mechanical Test Results• Microscopic Analysis• Cost Model
• Conclusion
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Conclusion• Gas Extraction is the key in OOA Technology• The Pressured applied by the AFP head plays an
important role in Debulking• Visual Inspection of Incoming tape is important• Compatible Strength of OOA Technology• Automated Manufacturing…Promising !• Controlled Voids Content and Fiber Volume• Cost Savings demonstrated
Future Work• Characterization of OOA Thick Laminates• OOA Sandwich structures
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THANK YOU !
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