Process Modeling and Analysis Tools for Thermoplastic Composite Missile Structures (MSC P4030)

Carbon fiber reinforced thermoplastic matrix composites (TPMCs) offer significant benefits for high performance composite structures for aviation and missile applications. Despite these advantages, TPMC materials and processing methods are not sufficiently characterized compared to most thermoset matrix composites. A better understanding of the influence of material forms and processing parameters on mechanical properties of the final product is needed. The research proposed here involves the development and validation of an improved methodology for modeling and analysis of the automated tape placement process of carbon fiber reinforced thermoplastic matrix composites. Model development and validation will be guided by prior modeling experience in the characterization of carbon fiber reinforced composites and extensive manufacturing experience with the in-situ automated tape placement process. Laboratory scale parametric experiments will be performed for different TPMC materials and ATP process conditions to guide the model development and characterize the influence of process conditions on material behavior and resulting properties.