Process Modeling and Analysis Tools for Thermoplastic Composite Missile Structures

The goal of this proposal is to develop and integrate a material process modeling tool into existing Automated Filament Placement (AFP) and Automated Tape Laying (ATL) infrastructure to have prediction capabilities over the mechanical performance of thermoplastic matrix fiber-reinforced composites (TPMCs). The proposed modeling tool is needed in order to produce consistent mechanical properties of manufactured composite structure. To this end, our goal is to capture effects of process parameters (heat rate, tooling temperature, applied pressure, tape angle orientation, varying crystalline structures) that directly alter the original mechanical properties of TPMCs. Although AFP and ATL advances processes enable large quantities of thermoplastic composites to be refined and parts fabricated to scale within a cost effective scope, the lack of process understanding inhibits accurate production and ultimately impacts the functionality of the composite material. The need to provide a modeling solution to enhance existing manufacturing equipment is crucial to the advancement of thermoplastic composite technologies. The Phase I work will conclude with the demonstration of the process modeling software that predicts the mechanical properties of TPMCs based on the process parameters and will provide a detailed comparison studies with the data in literature and those obtained from coupon-level tests.