In Situ Joining of Unidirectional Tapes on Long Fiber Reinforced Thermoplastic Structures by Thermoplastic Automated Fiber Placement for Scientific Sounding Rocket Applications
In Situ Joining of Unidirectional Tapes on Long Fiber Reinforced Thermoplastic Structures by Thermoplastic Automated Fiber Placement for Scientific Sounding Rocket Applications
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通过热塑性自动纤维铺放将单向带原位连接到长纤维增强热塑性结构上，用于科学探空火箭应用
DOI：
10.1016/j.procir.2019.09.015
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发表时间：
2019
期刊：
影响因子：
--
通讯作者：
K. Drechsler
中科院分区：
文献类型：
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作者：
R. Engelhardt;S. Ehard;Tobias Wolf;Jonathan Oelhafen;A. Kollmannsberger;K. Drechsler
自动纤维铺放允许自动铺叠航空航天质量的定制层压板。对于热塑性基体材料，使用闭环温度控制可实现原位固结。这使得高压釜固化多余，并提高了整体工艺效率。科学探空火箭通常由几个携带科学有效载荷的铝制模块组成。模块的设计包括一个圆柱形外壳和两个载荷输入环，具有定义的组装界面。减少结构重量将允许更高的有效载荷、更高的远距离飞行或减少燃料消耗。提出了一种新的制造概念，即采用热塑性自动铺丝（TP-AFP）工艺制造轻质复合材料模块，并重点研究了长纤维增强热塑性（LFT）结构上TP-AFP带的原位连接特性。这代表火箭模块负载输入环上圆柱形壳体的接头。通过单搭接剪切试验对两种不同取样面积的接头进行了表征，在室温和高温下，在预处理和未处理的LFT表面上进行了测试，结果表明，这些变化对接头的剪切强度没有显著影响。这些结果被考虑用于复合模块的设计，与铝模块相比，复合模块的重量减轻了40%以上。新模块在2019年3月作为探空火箭使命REXUS-23的一部分证明了其适航性。除了探空火箭，在复杂的LFT结构上原位粘结TP-AFP带的概念在航空航天和汽车结构中具有许多潜在的应用。
Automated Fiber Placement allows the automated lay-up of tailored laminates in aerospace quality. For thermoplastic matrix materials, the use of closed-loop temperature control enables an in situ consolidation. This makes autoclave curing superfluous and increases the overall process efficiency. Scientific sounding rockets typically consist of several aluminum modules carrying the scientific payload. The design of a module includes a cylindrical outer shell and two load input rings with a defined assembly interface. Reducing the structural weight would allow higher payloads, higher apogees or reduced fuel consumption. A new manufacturing concept using the Thermoplastic Automated Fiber Placement (TP-AFP) process was developed to manufacture a lightweight composite module.This paper presents the developed concept and focuses on the characterization of an in situ joint of TP-AFP tapes on a long fiber reinforced thermoplastic (LFT) structure. This represents the joint of the cylindrical shell on the load input rings of the rocket module. The joint was characterized with single lap shear tests for two different sample extraction areas at room temperature and at elevated temperature on pre-treated and untreated LFT surface.The variations did not show significant effects on the resulting shear strength. The results were considered for the design of the composite module allowing a weight reduction of more than 40 % compared to the aluminum modules. The new module proved its airworthiness as part of the sounding rocket mission REXUS-23 in March 2019. Beyond sounding rockets, the concept of in situ bonded TP-AFP tapes on complex LFT structures has many potential applications within aerospace but also automotive structures.