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Thermoplastic Composite Processing Using Superplastic Formed Magnesium Bladders

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Title: Thermoplastic Composite Processing Using Superplastic Formed Magnesium Bladders

Authors: Steven M. Shewchuk, Jared B Hughes, Corey M. Vasel and Gail L. Hahn

DOI: 10.33599/nasampe/s.20.0352

Abstract: This paper discusses a method of manufacturing thermoplastic composite parts using superplastic formed AZ31 magnesium bladders. This method superplastically forms magnesium against the composite part at temperatures lower than traditional superplastic forming temperatures and above thermoplastic composite melting temperatures to consolidate the thermoplastic composite. Historically, superplastic forming has been completed with pressurized argon gas. An investigation into the use of nitrogen gas was completed and the resulting parts were evaluated. The part configurations are evaluated for attenuation, surface roughness, and ply locations on a gentle contoured single sided tool surface with single use bladders. It was found that the use of nitrogen as compared to argon as a bladder pressurization gas had a negative impact on the part quality.

References: [1] A. Haufe, K. Schweizerhof, and P. Dubois, Properties and Limits: Review of Shell Element Formulations. Developer Forum 2013. Filderstadt, Germany. 24 September 2013. [2] LS-Dyna Keyword User’s Manual. Volume II, Material Models. LS-Dyna R8.0, 18 March 2015 [3] Taleff, E.M., Hector, L.G., Verma, R. et al. J. of Materi Eng and Perform (2010) 19: 488. https://doi.org/10.1007/s11665-010-9612-6 [4] Hahn, G.L., Tsotsis, T.K., “Rapid High-Performance Molding (RAPM) of Small Parts,” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019. [5] Shewchuk, S.M., Halford, B., Matlack, M.P., Sharpe, A. and Massey, P. “Development of Scalable Dynamic Control Architectures for Flexible Composites Manufacturing Work Cells.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019. [6] Schell, J.J., Shewchuk, S. M., Leach, D., McCrea, T., Abrams, N., Postera, R., and Hahn, G. L. “Rapid High Performance Molding of Structural Thermoplastic Composite Parts.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019.

Conference: SAMPE 2020 | Virtual Series

Publication Date: 2020/06/01

SKU: TP20-0000000352

Pages: 15

Price: FREE

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