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SAMPE Journal, Volume 52, No. 4, July/August 2016

Society for the Advancement of Material and Process Engineering

July/August 2016 Vol. 52, No. 4

www.sampe.org

Out-of-Autoclave (OOA) Technology


Society for the Advancement of Material and Process Engineering

FeaturesPage 7

Process Selection and Optimization for Out-of-Autoclave Prepreg Structures

Page 28

Out-of-Autoclave Fiber Placement Developments

Page 50

Rapid Out-of-Autoclave Composite Manufacturing for Aerospace-Grade Prepregs

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About the Cover Out-of-Autoclave (OOA) fiber placement pre-preg “head” contains numerous OOA prepreg CF materials in Ingersoll’s ‘Mongoose Head’ (left). Going clockwise, the first largest space payload fairing demonstrated by Boeing at SAMPE (upper right), followed by an Ingersoll fiber placement of OOA CF materials (center right), and second generation OOA materials flying on Spaceship 2 and White Knight 2 (bottom right).

July/August 2016 Vol. 52, No. 4www.sampe.org


Process Selection and Optimization for Out-of-Autoclave Prepreg Structures

C. RidgardCytec Aerospace Materials, Tulsa, OK

AbstractOut-of-autoclave (OOA) or vacuum bag only (VBO) prepregs depend on the physical extraction of entrapped air and volatiles to

achieve low levels of porosity, a tim e dependent process. Strategies for minimizing the total cure duration are discussed in several scenarios including cures completed exclusively in-tool, cures in which part of the process involves a freestanding postcure after demolding and sandwich parts in which the characteristics of both the prepreg and the film adhesive need to be considered. The use of short ‘super-ambient’ temperature dwells to replace previously used long dwells at room temperature is a focus of current work. Kinetic models provide a powerful tool in the development of optimum process conditions and examples involving CYCOM® 5320-1 prepreg and FM®309-1 adhesive are discussed.

Feature Article abstracts Feature Article abstract

Out-of-Autoclave Fiber Placement DevelopmentsR. W. Koon and S. C. ParsonsLockheed Martin Aeronautics Company, Marietta, GE

K. A. Povlitz and S. R. JirikLockheed Martin Aeronautics Company, Palmdale, CA

AbstractFiber placement of Out-of-Autoclave (OoA) epoxies presents unique challenges to high rate automated fabrication of composite

structures. Development efforts by Lockheed Martin Skunk Works® on MTM45®-1, in particular, have shown that, as compared to autoclave materials, fabrication of high quality OoA structures by fiber placement requires significant modifications to the hand lay-up prepreg form, higher temperature placement conditions, and close attention to material tack and outime levels. Recent efforts using Skunk Works® Ingersoll Mongoose AFP machine have fabricated a variety of MTM45®-1 articles from test panels, to elements, to complex wing skin structures, all of which have led to the formation of improved placement parameters. The lessons learned from these efforts have highlighted which changes in machine design and process parameters will have the greatest impact on improving the quality and cost of future OoA fiber placed structures.

Figure 7. Microcracks in a stratified MTM45-1/HM63 discriminator panel after a standard cure/postcure to 177°C and thermal cycling.

Figure 1. Ingersoll Mongoose Machine located in Palmdale, CA.


Feature Article abstracts Feature Article abstract

Rapid Out-of-Autoclave Composite Manufacturing for Aerospace-Grade PrepregsA. Haro, B. Lehman, K. Yoshioka, F. N. Nguyen B. Luedtke, D. BrosiusToray Composites (America), Inc., Tacoma, WA Quickstep Composites LLC, Dayton, OH

AbstractCurrent state-of-the-art composite manufacturing technologies developed for dual-aisle aircraft are limited to a low volume by

an exclusive use of an autoclave molding method. This method is both time-intensive and costly. Future composite aerospace applications for primary and secondary aircraft structures could demand a rapid part production rate with void-free quality in addition to exceptional performance. Notably, single-aisle aircraft would need innovative composite manufacturing technologies that are rapid and cost competitive enough to compete with current metal alloy processes. Researchers at Toray Composites (America), Inc. have investigated a rapid out-of-autoclave (OOA) molding method known as the Quickstep process. This process allows rapid heating/cooling with moderate compaction pressures to fabricate composites from prepregs. Two commercially available aerospace prepregs were utilized in the present study for a comparison among Quickstep, vacuum bag only (VBO) and autoclave. A non-interlayer toughened system demonstrated more than 50% total cycle time reduction compared to VBO and autoclave. In addition, a low void content of less than 1% was achieved with comparable mechanical properties to those from autoclave cure. On the other hand, an interlayer toughened system showed a marginal reduction in total cycle time but achieved void content of less than 2% and comparable mechanical properties to those from autoclave cure as well.

Figure 1. (a) Quickstep Process Schematic5-6, (b) Quickstep QSE250 Machine and curing chamber5-6.

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