Title: Automated Ply-by-Ply Lamination and In-Situ Consolidation of Thermoplastic Composite High-Contour Stiffeners for High-Rate Aircraft Manufacturing

Authors: Nathaniel H. Gasteyer, Susan A. Rich, Vernon M. Benson, Benjamin D. Hill, Grace M. Butkus, Andrew C. Quayle, Derek S. King, Samuel L. Chen, Travis S. Olsen, Nathan K. Nyman, Ruben J. Salazar, Jacob A. Reifsnyder

DOI: 10.33599/nasampe/s.24.0170

Abstract: To meet the future demand of the commercial aircraft market, composite aircraft manufacturing rates must significantly increase. NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses this need to advance aircraft composite manufacturing technologies. Thermoplastic composites offer a promising solution to these manufacturing demands and present an opportunity for Northrop Grumman to bring the benefits of its Automated Stiffener Forming (ASF) technology to thermoplastic processing. Within HiCAM, Northrop Grumman is evolving the ASF technology for ply-by-ply, in-situ processing of thermoplastic composite materials. The modular process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for thermoplastics, heating technologies and roller compaction processes were investigated by manufacturing flat test coupons. These panels were evaluated by photo-microscopy, non-destructive inspection, and short beam shear tests and results were compared against baseline autoclave coupons. The results of the laminates fabricated via ASF are presented.

References: [1]Hi-Rate Composite Aircraft Manufacturing Project. (2024, January 18). Retrieved from NASA: https://www.nasa.gov/directorates/armd/aavp/hicam [2]Clean Sky 2 Programme overview and structure. (2024, January 18). Retrieved from Clean Aviation: https://www.clean-aviation.eu/clean-sky-2/programme-overview-and-structure [3]Mason, K. (2019, April 2). Spar forming simplified. CompositesWorld. [4]Toray Cetex® TC1225 Product Data Sheet. (2024, January 18). Retrieved from Toray Advanced Composites: https://www.toraytac.com/product-explorer/products/gXuK/Toray-Cetex-TC1225

Conference: SAMPE 2024

Publication Date: 2024/05/20

SKU: TP24-0000000170

Pages: 15

Price: $30.00