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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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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
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
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
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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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
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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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
Thermoplastic Composites for Space
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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
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
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
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
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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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
• 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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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
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
B.R. Murray, D.M. Grogan, S.B. Leen, C.M. Ó Brádaigh
Lightweight Thermoplastic Composite Fuel Tanks for Space
Applications
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
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
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.
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
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ap
wid
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m)
Ave
rag
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OD
(μ
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
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
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
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
• 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.
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
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
Fuel Cylinder Manufacture
Fuel Cylinder Testing
• Cylinder with speckled finish for DIC
• Cylinder held in buckled position, diamond pattern
• Thermoplastics for Space - Why ?
• Automated Tape Placement Development
• Cryogenic Fuel Tanks
• Launcher Interstage Structure
• Conclusions and Future Developments
• Payload Adapter Fairing
Presentation
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
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
Stiffened Panel Buckling
• Stiffened Panel Buckling Test to measure capacity
• Strain gauges and pattern on surface
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
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
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
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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Out-of-Autoclave Processing of Advanced Thermoplastic Composites for Space Fuel Tanks and Launchers – C. Ó Brádaigh
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
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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
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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