Innovative Methods for Thermoplastic Composites on ATL/AFP

Thermoplastic composites materials have shown potential to surpass the properties of aerospace thermoset composites for many years. However, the rigid material form, high processing temperatures and high cost have rendered them impractical for most warfighter applications. Recent advances in lower-cost automation, improved material processability / cost and precision heating systems have demonstrated promise to provide more economical and robust aerospace structures than conventional thermosets. Automated Fiber Placement (AFP) equipment for thermoplastic composites is commercially available from a number of manufacturers. However, there are still limitations on the speed and quality of the composite material produced by these machines, primarily due to the lack of sufficient process time to develop full interlaminar mechanical properties. This study intends to optimize those interlaminar properties using state-of-the-art, commercially available AFP equipment and quantify those properties to determine if they can achieve properties similar to common aerospace thermoset composites. Once optimized, a small part, representative of an aircraft structure shall be fabricated and assessed. This investigation will guide future studies in the optimization of those properties, while improving cycle time and cost. Research topics include: , methods to promote rapid polymer chain interdiffusion, process modeling, alternate heat source studies, low-cost tooling and adaptable tool heating/cooling.