Title: INFLUENCE OF MATERIAL FORM ON FABRICATION OF THERMOPLASTIC COMPOSITE WINDOW FRAME

Authors: Rich Postera, David Leach

DOI: 10.33599/nasampe/s.23.0165

Abstract: Aircraft window frames represent an attractive opportunity for rapid fabrication using thermoplastic composites. They are moderate size and are used in large quantities per aircraft which provides a good economic case for thermoplastic fabrication. Window frames have a complex geometry which can provide a challenge for successful forming. A representative window frame was designed and a stamp forming tooling was developed to assess forming. A range of material forms were evaluated to assess the fabrication characteristics. The forms included carbon fiber unidirectional tapes in various lay-ups, fabric, and mat reinforcements, all with PPS matrices. Frames incorporating lightning strike mesh were also evaluated. Modeling of the forming process was conducted to assess predicted forming and potential anomalies. Window frames were fabricated using the stamp forming process and the frames were evaluated using non-destructive and destructive inspection methods. The features in the formed parts were compared to the models to assess forming predictions. Through this investigation recommendations can be made for the material forms and fabrication conditions for successful window frame fabrication

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Conference: SAMPE 2023

Publication Date: 2023/04/17

SKU: TP23-0000000165

Pages: 15

Price: $30.00