Pultrusion of Carbon Fiber Reinforced Thermoplastic Composites

Recent progress in the availability of low cost reinforced thermoplastic unidirectional tape provides a family of alternative composite systems for pultruded structures. Cost effective pultrusion of carbon fiber reinforced thermoplastic resins will be demonstrated in the Phase I effort of this program. A significant increase in speed is expected with the use of pre- impregnated material that is not dependent on resin reactivity. Two part profiles will be selected that represent geometries of value to aerospace and commercial users. The structural properties and weight reduction afforded by the use of carbon fiber, as opposed to glass, will be emphasized. Feedstock products include unidirectional, biaxial and braided tape to provide the range of fiber orientation in an easy to use format. Pultrusion parameter development will identify the critical factors that are key to the production of a quality carbon fiber composite. Thermal energy management will be a primary focus of effort to establish oven residence time, tool die temperature profile and material cooling rates. A team, to work with Quadrax, has been assembled to build upon the expertise of Morrison Molded Fiber Glass, Lockheed and Composite Structures for pultrusion, airframe manufacturing and carbon fiber structures respectively. Anticipated Benefits/Potential Applications - The current composite market for carbon fibers opens many opportunities within the aerospace and commercial markets for improving performance competition. High modulus material permits greater composite use in areas previously not accessible. Reinforced thermoplastic resins have opened new markets for pultruded products requiring chemical resistance, structural enhancement, formability, welding and damage tolerance.