PFI-TT: Advanced Prepreg Materials for Robust, Low-Cost Manufacture of Composite Structures

PFI-TT：用于稳健、低成本制造复合结构的先进预浸材料

• 批准号: 1827788
• 负责人: Steven Nutt
• 金额: $ 20万
• 依托单位: University of Southern California
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2018
• 资助国家: 美国
• 起止时间: 2018-08-15 至 2021-03-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1827788&HistoricalAwards=false
• 关键词: PFI; TT; Advanced; Prepreg; Materials

The broader impact/commercial potential of this PFI project includes lowering production costs and cost-related entry barriers for the manufacturing of composite structures in aerospace, wind energy, defense, and other fields. The proposed technology will allow customers to effectively and reliably control process-induced defects during production, reducing rates of part rejection or rework, production costs, and cycle times, while increasing manufacturing efficiency and robustness. Moreover, the materials manufactured with the proposed technology will provide a viable solution for in-field repair of composites, replacing problematic legacy methods and disrupting an area poised for growth. Educationally, the project will provide opportunities to train participants in technology advancement and commercialization, and will foster cooperation between academic and industry participants. Scientifically, the project will contribute to a deeper and broader understanding of engineering science and technology associated with composite materials and production processes. Societally, the project will increase U.S. technical competitiveness in composites, advanced materials, and advanced manufacturing across multiple sectors of national interest, create jobs, and contribute to economic growth and long-term prosperity.The proposed project will develop material and process technologies that address long-standing efficiency and robustness challenges associated with manufacturing of composite structures. Many sectors, including aerospace, seek to utilize low-pressure out-of-autoclave (OoA) processing to improve production rates and reduce costs. However, commercial OoA prepreg materials (fibers impregnated with liquid resin) possess a sub-optimal design that results in unacceptable defects in non-ideal manufacturing conditions. This project will develop methods for producing advanced prepregs with an optimized format by combining partial impregnation and a discontinuous resin distribution. The project team will (1) develop industrially-scalable production methods, (2) create prototype materials for two applications with strong market needs (aerospace structure fabrication, and in-field repair), and (3) perform scale-up trials in realistic conditions for validation and demonstration. These activities require knowledge, use, and control of complex physical processes, including deformation of multi-scale fiber beds, multi-phase fluid flow, and microstructural defect formation. Technical work will advance knowledge in advanced manufacturing, materials science, and composites processing, and lead to viable methods for producing innovative prepregs. Overall, the project will derive intellectual merit from leveraging and applying fundamental insights, developing new science-based materials and systems, and providing a technical basis for further advancement.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

该PFI项目的广泛影响/商业潜力包括降低航空航天、风能、国防和其他领域复合材料结构制造的生产成本和与成本相关的进入壁垒。提出的技术将允许客户在生产过程中有效和可靠地控制过程引起的缺陷，减少零件拒收或返工率，生产成本和周期时间，同时提高制造效率和稳健性。此外，采用所提出的技术制造的材料将为复合材料的现场修复提供可行的解决方案，取代有问题的传统方法，并破坏一个蓄势增长的领域。在教育方面，该项目将提供培训技术进步和商业化参与者的机会，并将促进学术界和工业界参与者之间的合作。在科学方面，该项目将有助于更深入、更广泛地了解与复合材料和生产工艺相关的工程科学和技术。在社会方面，该项目将提高美国在复合材料、先进材料和先进制造领域的技术竞争力，跨越多个国家利益部门，创造就业机会，并为经济增长和长期繁荣做出贡献。拟议中的项目将开发材料和工艺技术，以解决与复合材料结构制造相关的长期效率和稳健性挑战。包括航空航天在内的许多行业都在寻求利用低压高压灭菌器外（OoA）加工来提高生产率并降低成本。然而，商用OoA预浸材料（液体树脂浸渍的纤维）具有次优设计，在非理想的制造条件下会导致不可接受的缺陷。该项目将开发通过结合部分浸渍和不连续树脂分布，以优化格式生产先进预浸料的方法。项目团队将(1)开发工业可扩展的生产方法，(2)为两种具有强大市场需求的应用（航空航天结构制造和现场维修）创建原型材料，以及(3)在现实条件下进行放大试验，以进行验证和演示。这些活动需要了解、使用和控制复杂的物理过程，包括多尺度纤维床的变形、多相流体流动和微观结构缺陷的形成。技术工作将推进先进制造、材料科学和复合材料加工方面的知识，并导致生产创新预浸料的可行方法。总体而言，该项目将从利用和应用基础见解、开发新的科学材料和系统以及为进一步发展提供技术基础中获得智力价值。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

项目成果

Design and application of discontinuous resin distribution patterns for semi-pregs

半浸料不连续树脂分布模式的设计与应用

• DOI: 10.1080/20550340.2020.1736864
• 发表时间: 2020
• 期刊: Advanced Manufacturing: Polymer & Composites Science
• 作者: Schechter, Sarah G.;Grunenfelder, Lessa K.;Nutt, Steven R.
• 通讯作者: Nutt, Steven R.

Air evacuation and resin impregnation in semi-pregs: effects of feature dimensions

半浸料中的排气和树脂浸渍：特征尺寸的影响

• DOI: 10.1080/20550340.2020.1768348
• 发表时间: 2020
• 期刊: Advanced Manufacturing: Polymer & Composites Science
• 作者: Schechter, Sarah G.;Grunenfelder, Lessa K.;Nutt, Steven R.
• 通讯作者: Nutt, Steven R.

Process robustness and defect formation mechanisms in unidirectional semipreg

单向半浸料的工艺稳健性和缺陷形成机制

• DOI: 10.1080/20550340.2020.1834789
• 发表时间: 2020
• 期刊: Advanced Manufacturing: Polymer & Composites Science
• 作者: Edwards, William T.;Martinez, Patricio;Nutt, Steven R.
• 通讯作者: Nutt, Steven R.

Effect of Fiber Bed Architecture on Single Resin Droplet Spread for Prepreg Manufacturing

纤维床结构对预浸料制造中单树脂液滴铺展的影响

• 发表时间: 2020
• 期刊: SAMPE journal
• 影响因子: 0.2
• 作者: Martinez, P.;Jin, B.;Nutt, S.
• 通讯作者: Nutt, S.

Fast cure of stable semi-pregs via VBO cure

通过 VBO 固化快速固化稳定的半浸料

• DOI: 10.1080/20550340.2020.1869891
• 发表时间: 2020
• 期刊: Advanced Manufacturing: Polymer & Composites Science
• 作者: Bender, David B.;Centea, Timotei;Nutt, Steven
• 通讯作者: Nutt, Steven