Title: Revolutionizing Molding Accuracy for Aviation and Urban Air Mobility: The Power of Low Thermal Expansion Tooling in CFRTP Compression Molding

Authors: Hiromichi T. Fujii, Haruyasu Ohno, Naoki Sakaguchi, Shingo Matsumura, Kotaro Ona, Junichi Go, Umito Yoshioka

DOI: 10.33599/nasampe/c.24.0237

Abstract: Unidirectional and woven carbon fibers prepregs using four types of thermoplastic resins with different molding temperatures were prepared for the compression molding tests. The resins used in prepregs were PP, PA6, PPS and PEEK, and forming was conducted at 200ºC, 260ºC, 350ºC and 400ºC, respectively. A tooling used for compression molding was made of a low thermal expansion (LTE) alloy (Fe-Ni-Co based alloy), and for comparison, a tooling made of a typical tool steel for plastic molding was also prepared. The shape accuracy of the plate specimens was assessed using 3D shape measurement equipment. The use of LTE tooling was found to significantly enhance the shape accuracy of press-formed CFRTP plates. In particular, the flatness of the PEEK plate, estimated from the ratio between the maximum height and the diagonal length of a rectangle specimen, prepared with LTE tooling was 0.040%, a significant improvement over the 0.60% achieved with typical tooling. Furthermore, the use of LTE tooling also led to a significant improvement in the distortion of the intended shape. The flexural strength of PPS specimens with woven carbon fibers improved by approximately 12% when using LTE tooling, although the mechanical properties of most CFRTP test specimens remained unchanged compared to typical tooling. These significant enhancements in both dimensional accuracy and flexural strength highlight the potential benefits of LTE tooling for specific applications.

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Conference: CAMX 2024 | San Diego CA

Publication Date: 2024/9/9

SKU: TP24-0000000237

Pages: 19

Price: $38.00