Investigation of Fiber Filled Injection Molding Materials for Thermoplastic Composite Missile Structures (MSC P4241)

Fiber reinforced thermoplastic matrix composites (TPMCs) have gained increased attention for use in high performance composite structures and components for aviation and missile applications due to significant benefits for improved damage tolerance, faster processing and assembly, reduced joint weight, virtually unlimited shelf life with minimal storage requirements, and recycling options.Despite these advantages, TPMCs are not sufficiently characterized compared to most thermoset matrix composites.An improved understanding and characterization of the influence of material forms and processing parameters on the mechanical properties of the final product is needed to achieve more efficient TPMC product design and successful integration for future aviation and missile structures. The primary objective of this Phase II program is to develop and demonstrate an improved design and analysis strategy that will facilitate more efficient development, evaluation, and implementation of lightweight, high performance fiber filled IM TPMC structures. This strategy will be applied to directly support ongoing AMRDEC and Project Office initiatives involving the design, evaluation and qualification of high performance TPMCs for aviation and missile systems. The proposed approach includes material and subcomponent characterization, material failure analysis and flow model parameter development, and demonstration and test article fabrication, verification and validation.