Title: Manufacturing Process Considerations when Transitioning from Thermoset to Thermoplastic Composite Material for Urban Air Mobility Propellers

Authors: Samuel L. Jones, Darun Barazanchy, Joshua Widawsky, Wout De Backer

DOI: 10.33599/nasampe/s.22.0842

Abstract: Thermoset (TS) and thermoplastic (TP) composites can both be found on aerospace structures, yet the use of TS composites on primary structures vastly exceeds the use of TP composites. In part, this may be attributed to the processing methods of the two fiber-reinforced polymers, as greater processing temperatures needed to cure TP composites when compared to TS composite manufacturing. The thermal formability of TP composites opens the door to fastener-free assemblies which has the benefit of reducing weight without compromising joint strength or requiring extensive co-curing. TP structures also offer a more rapid consolidation, allowing high-rate manufacturing, as needed by the urban air mobility market (UAM). To further explore and contrast applicable manufacturing methods of both material systems, a manufacturing demonstrator concept was designed. A generic propeller blade model was used as the reference structure for this research. This particular propeller blade model was originally designed for TS composite manufacturing. Alternative manufacturing methods were explored to produce the same propeller blade using TP composite materials and processes. The result is a road map for design for manufacturing of TP composite structures when converting from TS composites.

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Conference: SAMPE 2022

Publication Date: 2022/05/23

SKU: TP22-0000000842

Pages: 12

Price: $24.00