Evaluation of Large Thermoplastic Welded Structure
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Thermoplastic↗
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Effect of Barely Visible Impact Damage on Thermoplastic Welded Structure
Spirit Aerosystems recently conducted screening tests on thermoplastic skin/stringer panels manufactured with Automated Fiber Placement (AFP) and stamp forming which were joined using Spirit’s Co-Fusion process. Skin and stringer gauge were both set to 0.168 cm. The resulting panel design is 48 cm tall, 49 cm wide, and has 3 stringers welded at a 21.5 cm pitch. Barely Visible Impact Damage (BVID) and Residual Compressive Strength were chosen to conduct a damage tolerance study. Zee stringers, made with IM8/PEKK-FC material, were Co-Fusion welded to a T1100/TC1225 skin. Out of these 5 panels, 1 was chosen to be a BVID survey panel, 1 for pristine compressive strength determination, and 3 to be impacted to create BVID followed by testing for residual compressive strength. On the survey panel, impacts ranged in energy from 40J – 65J and dent depth measurements were conducted at 24 hours, 48 hours, and two weeks after impacting. The residual compressive strength panel failed near the predicted load of 214 MPa. For the residual compressive strength panels, BVID was created at two different mid-bay locations: 1) striking the OML coincident with the stringer and 2) striking the skin IML 2.5 cm away from the stringer flange. Pulse Echo Ultrasonic Testing was used to inspect the panels before and after creating BVID.
HiCAM↗
Finite Element Thermal Model for Ultrasonic Welding of Thermoplastic Composites
Ultrasonic welding, UW, is a fast and energy-efficient technique for joining thermoplastic composites. It involves the use of high-frequency mechanical vibrations and a static welding force to melt and join adherends. Ultrasonic welding is an enabling technology to reduce the cost and complexity of in-space construction because lightweight thermoplastic composite components can be packaged compactly for launch and then efficiently assembled using supervised autonomous robotic technologies on site. However, the temperatures in space present challenges to UW, and it is critical that the efficacy of process parameters selected for manufacturing in space is understood prior to launch. To this end, a three-dimensional finite element model is presented in this technical presentation. The model incorporates equations for effects of viscoelastic heating and heat transfer on the welding process. The proposed model is applied to predict the temperature distribution in single lap shear, SLS, samples composed of AS4/PEEK (TC1200) composite that were welded using a terrestrial machine as part of a comprehensive weldability study. Thermocouple and infrared spot sensor data from the SLS samples provide empirical temperature measurements for calibration and validation of the UW thermal model. Calibration and validation of the model is an important step given the significant uncertainties in material properties such as the loss modulus and necessary assumptions in the physics implementations which allow the model to converge in an acceptable amount of time. The validated thermal model can be used to simulate the process for the space environment. Future validation sample testing is planned in a vacuum chamber. The result will be a model capable of guiding process parameter selection to ensure acceptable weld bonds when manufacturing in space.
Josh Fody↗
Innovations in Continuous Ultrasonic Welding of Thermoplastic Composites and Evaluation for Space Applications
The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include and assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities, including failure prediction of thermoplastic composites including joints. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite system were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding candidate materials by common welding techniques to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.
thermoplastic composite↗
Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications
The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include and assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities, including failure prediction of thermoplastic composites including joints. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite system were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding candidate materials by common welding techniques to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.
thermoplastic composite↗
Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications
The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include an assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite materials were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding of candidate materials to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.
thermoplastic composite↗
TDEA Thermoplastic Resistance Welding
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Allison Clark↗
Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications
The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include an assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities.1
thermoplastic composite↗
Toroid Joining Gun
The Toroid Joining Gun is a low cost, self-contained, portable low powered (100-400 watts) thermoplastic welding system developed at Langley Research Center for joining plastic and composite parts using an induction heating technique. The device developed for use in the fabrication of large space sructures (LSST Program) can be used in any atmosphere or in a vacuum. Components can be joined in situ, whether on earth or on a space platform. The expanded application of this welding gun is in the joining of thermoplastic composites, thermosetting composites, metals, and combinations of these materials. Its low-power requirements, light weight, rapid response, low cost, portability, and effective joining make it a candidate for solving many varied and unique bonding tasks.
Buckley, J. D.↗
Consolidation of Braided Carbon Fiber/ Thermoplastic Tubes by Induction Heating
Thermoplastic composites have experienced renewed enthusiasm within the U.S. aerospace industry, due in part to opportunities for rapidly manufacturing large structures. Unlike the lengthy cure cycles required by thermosets, the thermoplastic matrix prepreg requires only heat and pressure to consolidate consecutive layers of material; with sufficient inter-ply contact time to develop a strong interface. The manufacturing requirements for thermoplastics provide manufacturing flexibility and of particular interest are in-situ consolidation processes; i.e consolidation during layup on a tool. In-situ consolidation removes the time-consuming and costly secondary processing step of autoclave or press consolidation. Process variables which contribute to laminate quality include temperature, heat transfer, inter-ply contact time, and consolidation pressure. Most of the work to date related to in-situ consolidation has been in conjunction with automated fiber placement (AFP), where prepreg tows are consolidated when placed on the tool. Considering this process for a braided structure adds complexity relative to AFP due to the rapid lay-down rate of the braider and simultaneous placement of a multiple prepreg tows. Processes considered for consolidation during AFP could not be applied to a braided part. Alternatively, a fully braided preform could be consolidated on the tool using well established thermoplastic welding techniques. The goal of this effort was to evaluate the effectiveness of induction welding to consolidate braided carbon fiber/thermoplastic composite tubes up to eight plies in thickness. The manufacturing process, thermal characterization, and initial mechanical property data of the consolidated tubes are reported.
In-situ consolidation, induction heating/welding, ↗
Effect of Pressure in Thermoplastic Ribbon Thermal Welding
An inexpensive apparatus was designed to simulate some features of on-the-fly thermal welding in heated-head tow placement. Previous studies have shown how ply/ply weld strength depends on weld time/temperature history. The apparatus has been modified recently to apply higher contact forces. Welding at pressures up to 1.7MPa (250psi) produced more consistent welds and fewer intra-ply voids, This has permitted a study of the conditions required for achieving the limiting ply/ply cohesive strength in simulated tow placement of a polyimide oligomer.
Hinkley, J. A.↗
Consolidation of Braided Carbon Fiber/ Thermoplastic Tubes by Induction Welding
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In-situ consolidation↗
Modeling and Simulation of Thermoplastic Composite (AS4/PEEK) Resistance Welding With DIGIMAT
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Pierre-Yves Lavertu↗
Resistance Welding Simulation of a Thermoplastic Composite Lap Shear Coupon
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Crystallization kinetics↗
Development of a beam builder for automatic fabrication of large composite space structures
The composite material beam builder which will produce triangular beams from pre-consolidated graphite/glass/thermoplastic composite material through automated mechanical processes is presented, side member storage, feed and positioning, ultrasonic welding, and beam cutoff are formed. Each process lends itself to modular subsystem development. Initial development is concentrated on the key processes for roll forming and ultrasonic welding composite thermoplastic materials. The construction and test of an experimental roll forming machine and ultrasonic welding process control techniques are described.
Bodle, J. G.↗
Resistance welding graphite-fiber composites
High-strength joints are welded in seconds in carbon-reinfored thermoplastic beams. Resistance-welding electrode applies heat and pressure to joint and is spring-loaded to follow softening material to maintain contact; it also holds parts together for cooling and hardening. Both transverse and longitudinal configurations can be welded. Adhesive bonding and encapsulation are more time consuming methods and introduce additional material into joint, while ultrasonic heating can damage graphite fibers in composite.
Lamoureux, R. T.↗
Progress in composite structure and space construction systems technology
The development of deployable and fabricated composite trusses for large space structures by NASA and private industry is reviewed. Composite materials technology is discussed with a view toward fabrication processes and the characteristics of finished truss beams. Advances in roll-forming open section caps from graphite-composite strip material and new ultrasonic welding techniques are outlined. Vacuum- and gravity-effect test results show that the ultrasonic welding of graphite-thermoplastic materials in space is feasible. The structural characteristics of a prototype truss segment are presented. A new deployable graphite-composite truss with high packaging density for broad application to large space platforms is described.
Bodle, J. B.↗
Portable Welder
A low cost, low power, self-contained portable welding gun designed for joining thermoplastics which become soft when heated and harden when cooled was developed originally by NASA's Langley Research Center for repairing helicopter windshields. Welder has a broad range of applications for joining both thermoplastic materials in the aerospace, automotive, appliance, and construction industries. Welders portability and low power requirement allow its use on-site in any type of climate, with power supplied by a variety of portable sources.
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