Out-of-Autoclave Processing of Advanced Thermoplastic ...€¦ · ls es Out-of-Autoclave Processing...

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Institute for Materials and Processes Prof. Conchúr Ó Brádaigh University of Edinburgh, Scotland, UK Éire Composites Teo., Galway, Ireland Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers SAMPE UK and Ireland Chapter Annual Seminar, Feb. 24 th 2017

Transcript of Out-of-Autoclave Processing of Advanced Thermoplastic ...€¦ · ls es Out-of-Autoclave Processing...

Page 1: Out-of-Autoclave Processing of Advanced Thermoplastic ...€¦ · ls es Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers –C. Ó

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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh

Prof. Conchúr Ó BrádaighUniversity of Edinburgh, Scotland, UK

Éire Composites Teo., Galway, Ireland

Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel

Tanks and Launchers

SAMPE UK and Ireland Chapter Annual Seminar, Feb. 24th 2017

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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh

• Christopher Semprimoschnig, Simon Appel, Adriana Sirbi, ESTEC, Noordwijk, The Netherlands

• Keith Doyle, Adrian Doyle & Mike Flanagan, ÉireComposites

• Dipa Roy, University of Edinburgh

• Ioannis Manolakis, David Jones, Anthony Comer, Terry McGrail (ICOMP – Irish Composites Centre)

• David Grogan, Brendan Murray and Sean Leen, National University of Ireland, Galway

Acknowledgements

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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh

Personal Background / Edinburgh

• Chair of Materials Engineering, University of Edinburgh, October 2015-present

• Previously Professor at University College Cork (2014-2015) and Senior Lecturer at NUI Galway, (1990-2014)

Composites at Edinburgh

• Dr. Edward McCarthy, Lecturer (ex-U. of Manchester), started August 2016

• Dr. Dipa Roy, Lecturer (ex-ICOMP, University of Limerick), started Jan. 2017

• 5 PostDoc Researchers and 5 PhD students

• New labs being developed in testing and processing

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ÉireComposites & CTL• 60 staff in total, including 20 engineers – only

aerospace-accredited composites manufacturing

company in Republic of Ireland

• International customer base – Bombardier, Airbus,

Aircelle, Cytec, Lotus, GKN, Siemens, FAAC,

Scotrenewables, Suzlon Energy

• CTL accredited composites materials testing

facility - over 100 customers worldwide

• Advanced R&D in thermoplastic composites and

large heated tooling

• PRI Nadcap (Composites, Testing and NDT)

• EN/AS 9100, ISO 9001 2000 & ISO 17025

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Irish Composites Centre (IComp)

o IComp is an Enterprise Ireland & IDA funded

Technology Centre

o A partnership between University of Limerick, University

College Dublin, Athlone Institute of Technology and the

National University of Ireland Galway

o 21 members from Irish industry

o 3 Large Enterprises

o 18 SMEs

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Current IComp Members

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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh

• Thermoplastics for Space - Why ?

• Automated Tape Placement Development

• Cryogenic Fuel Tanks

• Launcher Interstage Structure

• Conclusions and Future Developments

• Payload Adapter Fairing

Presentation

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Thermoplastic Composites for Space

• Space launcher structures too large for autoclaves (Ariane 5: ø =5.4m, length over 30m)

• Possible to make large integrated TPC structures completely out-of-autoclave, using ATP and welding/joining, with close-to-autoclave properties

• CF/PEEK has good high temperature (150-180°C) and low temperature (-200°C) performance (stiffness, strength, fracture toughness)

• CF/PEEK also has good outgassing, microcracking, resistance to liquid H2 and LOX performance

• Integration of stiffeners using welding /joining/over-ATP of press-formed TPC parts

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Thermoplastic Composites for Space

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ESA Future Launchers (FLPP)

• Ariane 5 current space launcher (OD up to 5.4 m)

• Future Launchers Preparatory Programme (FLPP) started 2003

• Next Generation Launchers to replace Ariane 5

1. Cryogenic fuel tank – ø 500 mm demonstrator

2. Interstage structure – ø 1500 mm demonstrator

3. Payload Adapter fairing – ø 1200 mm max.

LH2

LOX

Metallic Cryo Tank

Fuel Permeability

Interstage Structure

Integration, Larger ø

Payload Adapter Fairing

More complex geometry for ATP

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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh

• Thermoplastics for Space - Why ?

• Automated Tape Placement Development

• Cryogenic Fuel Tanks

• Launcher Interstage Structures

• Conclusions and Future Developments

• Payload Adapter Fairing

Presentation

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ATP Facility at ICOMP

AFPT tape placement machine

• Laser Heat

• Consolidation Roller

• In situ consolidation

• CF/PEEK Tape

• 12mm wide, 0.125mm thick

Fibre Optic

Cable

Material Spool

Compaction

Roller

Laser Head

Pyrometric Camera ATP Tape

Direction of travel

Compaction Roller

Tool Surface

Incoming tape

Previous

plies

CF/PEEK Tape

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Material Characterisation

• Mechanical testing

• Tension, compression, flexure etc.

• Testing from +800C down to -1960C

• Conditioning/saturation of specimens

• Fibre and resin dominated tests

• Physical Testing

• Density

• Fibre volume fraction

• % crystallinity

• Outgassing – mass loss under vacuum

• LOX and LH2 testing

MECHANICAL TESTS

0° Tensile Strength

0° Tensile Modulus

0°/90° Poissons Ratio

90° Tensile Strength

90° Tensile Modulus

0° Compressive Strength

0° Compressive Modulus

90° Compressive

Strength

90° Compressive

Modulus

In-Plane Shear Strength

In-Plane Shear Modulus

Flexural Strength

Flexural Modulus

ILSS

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Inspection – Micro-sections

• Micrographs of ATP and Autoclave laminates

• Autoclave laminates more consistent quality with lower void content

• Larger resin rich areas between consecutive plies in ATP

• ATP process joints visible with resin rich areas between joints

Autoclave ATP

1.1mm

1 Ply

Tape process

ply-join

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• UD and multi-axial laminates manufactured (CF/PEEK)

• 0° flexure: 17% improvement over hot gas ATP

• 90° tensile: 58% improvement over hot gas ATP

ATP Development at ICOMP

Comparing previous hot gas ATP to laser ATP (University of Limerick, IComp and ÉireComposites)

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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh

DCB Panel

Lay-up [0°]30

Lay-down speed 8 m/min

Laser Power (1st ply) 1350 W

Tool Temperature 150°C

Roller Material Silicone

Roller Pressure* 1.2 Bar

Sample Type GIC Initiation

(KJ/m2)

GIC Arrest

(KJ/m2)

Autoclave 1.32 0.92

LATP 2.15 1.67

AUTOCLAVE ATP

DCB Test (Mode-I Fracture Toughness)

ATP Research – Comparison with Autoclave -(T 60% IM7/ PEEK-150) Suprem

Autoclaved laminate crystallinity c. 42%ATP laminate crystallinity c. 18%

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Flexural Strength:Autoclaved 100% (1775 MPa)ATP (150°C Tool) 68%ATP (Heated Tool-T@280°C) 79%ATP(Heated Tool- T@230°C) 77%

Flexural Modulus:Autoclaved 100% (141 GPa)ATP (150°C Tool) 88% ATP (Heated Tool- T@280°C) 103%ATP (Heated Tool- T@230°C) 116%

ILSS :

Autoclaved 100% (112 MPa) ATP (150°C Tool) 70% ATP (Heated Tool- T@280°C) 76%ATP (Heated Tool- T@230°C) 75%

Propagation of crack

underneath the surface

Brittle

fracture

DCB Crack surface

De-bonding

underneath the crack

surface

Mounting epoxy resin

DCB Fracture Surfaces

Autoclave

ATP

ATP Research - Effect of Heated Tooling

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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh

• Thermoplastics for Space - Why ?

• Automated Tape Placement Development

• Cryogenic Fuel Tanks

• Launcher Interstage Structure

• Payload Adapter Fairing

• Conclusions and Future Developments

Presentation

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B.R. Murray, D.M. Grogan, S.B. Leen, C.M. Ó Brádaigh

Lightweight Thermoplastic Composite Fuel Tanks for Space

Applications

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Cryogenic Cycling of CF/PEEKLaminates(Cycles from RT to -196°C)

• Typical micro-cracks found in some laminates after thermal cycling

• Investigation of CF/PEEK tapes from various suppliers

• Laminates tended to crack on first cycle or not at all (elastic behaviour)

• Effect of thickness (thicker laminates have increased cracking)

• Effect of layup (fibre direction) Quasi-Isotropic > Cross-Ply

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Cryogenic Cracking of Autoclaved Laminates(Cycles from RT to -190°C)

0° 45° 135° 90° 90° 135° 45° 0°

0

1

2

3

4

5

6

7

12

34

Cra

ck

De

ns

ity (

/cm

)

Ply

Cytec QI

• Quantitative analysis:

Defect distributions and

morphology

Crack density and crack opening

displacement

• Qualitative analysis:

Crack initiation and morphology

Through thickness leak paths

Voids

Crack

initiation

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Pre-cycling Post-cycling

QI = quasi-isotropic

CP = cross-ply

Microcracks:

[1]

Cryogenic Cracking of Autoclaved LaminatesComparison of Different CF/PEEK Tapes

Not all CF/PEEK Tapes Are Created Equal !

Grogan, D.M., Leen, S.B., Semprimoschnig, C.O.A. and Ó Brádaigh, C.M., “Damage Characterisation of Cryogenically Cycled Carbon/PEEK Laminates”, Composites Part A: Applied Science and Manufacturing, Vol. 66, pp. 237-250, 2014. doi: 10.1016/j.compositesa.2014.08.007.

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0

100

200

300

400

500

600

700

800

0.0

0.5

1.0

1.5

2.0

2.5

3.0

1 2 3 4 5 6 7 8 9

Ave

rag

e g

ap

wid

th (μ

m)

Ave

rag

e C

OD

m)

Ply group

Microcracks

Gaps

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• Quantitative and qualitative

analyses similar to autoclave

specimens

• Additional manufacturing

defects in the form of filled

and non-filled gaps

Voids

Gap

Cryogenic cracking of TPC LaminatesTape-Laid

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Helium Permeability Testing

• Permeability performance of composites key design driver

• Repeated thermal cycling to -2000C- microcracking

• 100mm diameter composite test specimen

• Mounted between upper and lower chambers

• Upper Chamber + pressure Helium

• Lower Chamber – 1bar Vacuum

• Lower chamber connected to mass spectrometer

• Mass spectrometer measures leakage rate of helium

• Immersed in Dewar

• Verification of test setup using reference materials

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Permeability Testing

• Typical Leakage curve for CF/PEEK autoclave-consolidated laminate

• 30 hours to reach final leakage value

• Leak rate: 3.32xE-05 scc/sm2

• Units: standard cubic centimetres per second per metre squared

1.E-07

1.E-06

1.E-05

1.E-04

1.E-03

0 5 10 15 20 25 30 35

Time (Hours)

Le

ak

ra

te (

sc

c/s

m2)

Autoclave

Reference

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Permeability Results at Cryogenic

Temperatures

• Permeability of CF-PEEK is low enough for cryogenic fuel storage.

Behaviour of autoclaved laminates is Fickian.

• Permeability of un-cycled CF/PEEK at -196°C is several orders of

magnitude less than that measured at room temperature.

• Cryogenically-damaged laminates can exhibit non-Fickian behaviour

• ATP samples showed a higher leak rate and non-Fickian behaviour in

the as-manufactured state. This was attributed to manufacturing

defects in the laminates.

• For all samples, cryogenic cycling had little effect on the leak rate of

CF-PEEK unless cycling caused micro-cracking of the composite

matrix.

• Polymer liners should be investigated for cryogenic

fuel tanks

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• X-ray CT scans were used to determine the DCOD in CF/PEEK laminates

• These assessments were used, in conjunction with equations developed

by Nair & Roy, to determine the laminate permeability

Composite Overwrapped pressure Vessels (COPVs)

- DCOD Measurements and Predicitons

[15]

[15] Nair & Roy. Comp. Sci. Tech., 2007.

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Linerless COPVs- XFEM 3-D Model Development

• From 2-D unit cell to full 3-D

• Random microcracking

• DCOD measurements

• Through thickness leak paths

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Linerless COPVs- XFEM Microcracking and Permeability

• Crack opening values compared

with microscopy measurements

• Calculated permeability of

3.60 x 10-3 scc/m2s

• Experimental values in range of

2.50 x 10-1 to 8.50 x 10-5 scc/m2s

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Fuel Cylinder Demonstrator

• Cylinder Ø500mm x 700mm long

• Lay-up = [-45,45,90,0,90,0,90,0,90]s

• Nominal Thickness = 2.5mm

• Heated Tool at 280oC

• Ply paths generated using MATLAB

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Fuel Cylinder Manufacture

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Fuel Cylinder Testing

• Cylinder with speckled finish for DIC

• Cylinder held in buckled position, diamond pattern

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• Thermoplastics for Space - Why ?

• Automated Tape Placement Development

• Cryogenic Fuel Tanks

• Launcher Interstage Structure

• Conclusions and Future Developments

• Payload Adapter Fairing

Presentation

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Interstage Structure (Unpressurised)

• Manufacturing

• ATP with in-situ consolidation - cylindrical shell

• Press forming long omega stiffeners/frames + curves

• Assembly and Joining – Induction Welding

• Testing

• Breadboards

• Large sub-scale demonstrator 1/3 scale (ø1500mm)

• Design

• FEA methods

Interstage

Structure

Axial

Stiffeners

Circumferential

Frame

Cylinder Shell

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Induction Welding Setup

• High Frequency generator

• Chiller runs water through the coil

and transformer

• Pyrometer measures temp on surface and

uses feedback loop to regulate induction

Welded Aircraft CF/PEEK Flap Demonstrator

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Stiffened Panel Buckling

• Stiffened Panel Buckling Test to measure capacity

• Strain gauges and pattern on surface

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Test Results

• Buckling load = 350kN (35,000kg load on 1 kg composite panel)

• Buckling mode = global column

• Panel Failure Load = 380kN

Start of Test Buckling Stage

Side View

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Interstage Structure Design

Ø1.5m CF/PEEK

Skin

Process - ATP

Doublers

Steel Interface

Rings

¼ segments

Steel Interface

Rings

40 x CF/PEEK Axial

Stringers

Process – Press

Consolidation

10 x CF/PEEK Frames

Process – Press

Consolidation

1276mm626mm

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Structure Test at NUIG

Compression and bending test of composite stiffened cylinder

225kN ram

1 x 250kN ram

1 x 650kN ram

6m I beams

Cameras for 3D

Digital Image

Correlation

Diffusion structure

Test article

Hard floor

1m

Expected

Failure

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Structure Test Facility at NUIG

• 10 x 6 m² strong floor area

• 225kN, 250kN, 650kN load capacity actuators

• Zwick software-controlled

• 3D Dantec Digital Image Correlation

Large access

door

Reaction

frame

Hard floor

2.5 m high5 m long

5 m wide

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Publications• D. Ray, A.J. Comer, J. Lyons, W. Obande, D. Jones, R.M. O Higgins and M.A. McCarthy,

Fracture Toughness of Carbon Fibre/Polyether Ether Ketone Composites Manufactured by

Autoclave and Laser-Assisted Automated Tape Placement, J. APPL. POLYM. SCI. 2015, DOI:

10.1002/APP.41643

• A.J. Comer, , D. Ray, W.O. Obande, D. Jones, J. Lyons, I. Rosca, R.M. O’Higgins, M.A.

McCarthy, Mechanical characterisation of carbon fibre-PEEK manufactured by laser-assisted

automated-tape-placement and autoclave, Composites Part A, vol-69, February 2015, pp. 10–20

• Grogan, D.M., Ó Brádaigh, C.M., McGarry, J.P. and Leen, S.B., “Damage and Permeability in

Tape-Laid Thermoplastic Composite Cryogenic Tanks”, Composites Part A: Applied Science

and Manufacturing, Vol.78, pp. 390-402, 2015. doi:10.1016/j.compositesa.2015.08.037

• Grogan, D.M., Leen, S.B. and Ó Brádaigh, C.M., “A Combined XFEM and Cohesive Zone

Model for Composite Laminate Microcracking and Permeability”, Composite Structures,, Vol.

120, pp. 246-261, 2015. doi: 10.1016/j.compstruct.2014.09.068

• Grogan, D.M., Leen, S.B. and Ó Brádaigh, C.M., “An XFEM-Based Methodology for Fatigue

Delamination and Permeability in Composites”, Composite Structures, Vol. 107, pp. 205-218,

2014. doi:10.1016/j.compstruct.2013.07.050

• Murray, B.R., Semprimoschnig, C.O.A, Leen, S.B. and Ó Brádaigh, C.M., “Helium

Permeability of Polymer Materials as Liners for Composite Overwrapped Pressure Vessels”,

Journal of Applied Polymer Science, Vol. 133, 29, pp. 43675, 2016, doi: 10.1002/app.43675

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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh

• Thermoplastics for Space - Why ?

• Automated Tape Placement Development

• Cryogenic Fuel Tanks

• Launcher Interstage Structures

• Conclusions and Future Developments

• Payload Adapter Fairing

Presentation

Page 43: Out-of-Autoclave Processing of Advanced Thermoplastic ...€¦ · ls es Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers –C. Ó

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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh

Challenges:

• Achieving cost-effective bespoke TPC tapes and hence cost-effective parts

• Achieving desired crystallinity (CF/PEEK Composites) in the ATP processed part – for optimum balance of stiffness and toughness

Future Research:• Developing good quality ATP prepreg tape with desired dimensions, voids

and crystallinity levels

• Develop multifunctional tapes ?

• Understanding the effect of process parameters (lay-down speed, roller temperature & pressure etc.) on final properties

• Investigating the tape welding/melting behaviour under laser and development of crystallinity across the thickness of the laminate

• Reducing the need for heated tools

• Develop cost effective polymer liners (rotomoulding of PEEK)

ATP Materials and Processes – Future Work

Page 44: Out-of-Autoclave Processing of Advanced Thermoplastic ...€¦ · ls es Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers –C. Ó

Inst

itu

te f

or

Ma

teri

als

an

d P

roce

sses

Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh

• Thermoplastics for Space - Why ?

• Automated Tape Placement Development

• Cryogenic Fuel Tanks

• Launcher Interstage Structures

• Conclusions and Future Developments

• Payload Adapter Fairing

Presentation