Title: Joining, Disassembly, and Reconfiguration of Thermoplastic Composites for Space Applications

Authors: Joseph J. Pinakidis, Sandi G. Miller

DOI: 10.33599/nasampe/c.24.0226

Abstract: Thermoplastic composites are increasingly being investigated for aerospace applications because of their relatively short processing time, good chemical and radiation resistance, and potential for reforming and reuse via melting. The manufacturing, reforming, and reuse of thermoplastic composites can be leveraged to advance joining, disassembly, and on-site reassembly of structures for space exploration activities. Potential applications include, but are not limited to, habitats and on-orbit assembly and reassembly of large-scale truss structures. This work focuses on demonstrating the feasibility of joining, disassembly, and reassembly of a thermoplastic bond using heat and pressure. Polyether ether ketone (PEEK) composite adherends were joined using low-melt polyaryl ether ketone (LM-PAEK) thermoplastic films at the bonding interface. The single lap shear specimens with LM-PAEK film were tested and had a maximum shear strength between 5 and 8 MPa and consistently failed adhesively at the bondline. Reassembly of disassembled specimens was successfully demonstrated using additional thermoplastic interlayers. Thus, the reassembly of thermoplastic composite joints was found to be feasible. However, additional work is required to reduce film flowout and optimize consolidation parameters for an in space environment.

References: [1] Alshammari, Basheer A., et al.: Comprehensive Review of the Properties and Modifications of Carbon Fiber-Reinforced Thermoplastic Composites. Polymers, vol. 13, no. 15, 2021, p. 2474. [2] Vodicka, Roger: Thermoplastics for Airframe Applications: A Review of the Properties and Repair Methods for Thermoplastic Composites. DSTO–TR–0424, 1996. [3] Zeyrek, B.Y., et al.: Review of Thermoplastic Composites in Aerospace Industry. Int. J. Eng. Tech. Inf., vol. 3, 2022, pp. 1–6. [4] August, Zachary, et al.: Recent Developments in Automated Fiber Placement of Thermoplastic Composites. SAMPE J., vol. 50, no. 2, 2014, pp. 30–37. [5] Barroeta Robles, J., et al.: Repair of Thermoplastic Composites: An Overview. Adv. Manuf.: Polym. Compos. Sci., vol. 8, no. 2, 2022, pp. 68–96. [6] de Weert, Loic: Disassembly of Fusion Bonded Thermoplastic Composite Joints Aided by Induction Heating: Effects of Induction Heating on Disassembly Force and Damage Patterns. Master’s thesis, Delft Univ. of Technology, 2021. [7] Frederick, Harry; Li, Wencai; and Palardy, Genevieve: Disassembly Study of Ultrasonically Welded Thermoplastic Composite Joints via Resistance Heating. Materials, vol. 14, no. 10, 2021, p. 2521. [8] Haq, Mahmoodul, et al.: Tailorable Adhesives for Multi-Material Joining, Facile Repair and Re-Assembly. Proceedings of the American Society for Composites 2015—Thirtieth Technical Conference, Michigan State University, East Lansing, MI, 2019. [9] Koutras, N.; Villegas, I.F.; and Benedictus, R.: Influence of Temperature on Strength and Failure Mechanisms of Resistance Welded Thermoplastic Composites Joints. 20th International Conference on Composite Materials, Copenhagen, Denmark, 2015. [10] Palardy, Genevieve, et al.: A Study on Amplitude Transmission in Ultrasonic Welding of Thermoplastic Composites. Compos. Part A Appl. Sci. Manuf., vol. 113, 2018, pp. 339–349. [11] Palardy, Genevieve; and Villegas, Irene Fernandez: On the Effect of Flat Energy Directors Thickness on Heat Generation During Ultrasonic Welding of Thermoplastic Composites. Compos. Interfaces, vol. 24, no. 2, 2017, pp. 203–214. [12] Kirby, Madeline; Naderi, Armaghan; and Palardy, Genevieve: Predictive Thermal Modeling and Characterization of Ultrasonic Consolidation Process for Thermoplastic Composites. J. Manuf. Sci. Eng., vol. 145, no. 3, 2023, p. 031009. [13] Li, Wencai; Frederick, Harry; and Palardy, Genevieve: Multifunctional Films for Thermoplastic Composite Joints: Ultrasonic Welding and Damage Detection Under Tension Loading. Compos. Part A Appl. Sci. Manuf., vol. 141, 2021, p. 106221. [14] ASTM D5868: Standard Test Method for Lap Shear Adhesion for Fiber Reinforced Plastic (FRP) Bonding. ASTM International, West Conshohocken, PA, 2014.

Conference: CAMX 2024 | San Diego CA

Publication Date: 2024/9/9

SKU: TP24-0000000226

Pages: 13

Price: $26.00