Out-Of-Autoclave

Advanced Materials International Forum – Bari - Italy
September 18th – 19th, 2014
Recent developments in out-of-autoclave processing
of fibre reinforced plastics
Session 3
“Advanced Materials: a key driver for business competitiveness”
Business Sector Focus: Aerospace
Ronald Klomp – de Boer
- R&D Engineer Composites @ NLR
Nationaal Lucht- en Ruimtevaartlaboratorium – National Aerospace Laboratory NLR
Out-Of-Autoclave: in general
Oven
Autoclave
Infusion (RTM, VARTM, etc.)
(pressure-cooker)
Press (Compression Molding, SMC,
BMC, etc.)
Aerospace standard and
grade
Autoclave great, but unaffordable
for rest of industry:
Automotive
Maritime
Tooling, Etc.
AMIF – Bari - Italy Sept. 18–19, 2014
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Out-Of-Autoclave; why?
Oven
Infusion
Press
Investment oven of
equivalent size & temp.
Lower than autoclave
Resin & fibres separate
 “cheaper”
Attractive for large series
Enabling very large,
integral composite
structures
Preform has no outlife
Complex geometries
Increased production
flexibility
Large integral structures
with VARTM
Integration of inserts
Reduced core
crush/stabilsation
problems
Complex, close tolerance
parts with RTM
Close tolerance
Repairs of same quality
as original
Repairs of same quality
as original
Possible lower tool costs
AMIF – Bari - Italy Sept. 18–19, 2014
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Out-Of-Autoclave; examples Industry
AMIF – Bari - Italy Sept. 18–19, 2014
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Out-Of-Autoclave; examples Aerospace
AMIF – Bari - Italy Sept. 18–19, 2014
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Out-Of-Autoclave; why not?
 Laminate quality
 Process control
 Process duration
 Performance
 Out-life
 Fibre volume content
 Etc.
All of the above processes are just not as well established
yet in aerospace as autoclave...but we’re getting there.
AMIF – Bari - Italy Sept. 18–19, 2014
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OOA: Oven Vacuum Bag only
Examples of work at
NLR:
Challenges:
 IM7-BMI OOA
prepreg for AFP
 5320 slit tape AFP
 Glass MTM45-1
fabric for engine
nacelle
AMIF – Bari - Italy Sept. 18–19, 2014
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OOA: Oven Vacuum Bag only
Work done and required
 Contact with material supplier
essential
 Quality and material specifics
(e.g. resin %)
 Processing; from lay-up to
bagging and curing really
different from autoclave
 OOA process simulation tools:
air evacuation  similar as
already partly available for
infusion
AMIF – Bari - Italy Sept. 18–19, 2014
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OOA: Infusion
Examples of work at
NLR:
Challenges: e.g. dry spots
 BMI vacuum
infusion
 Landing gear
component DFP
preform & RTM
 Vacuum infusion
DFP preforms
AMIF – Bari - Italy Sept. 18–19, 2014
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OOA: Infusion
AMIF – Bari - Italy Sept. 18–19, 2014
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OOA: Infusion
Work required:
 Adequate manufacturing simulation tools: infusion
process from A to Z improvements
 (constant) improvement of infusion resin mechanical
properties  compete with prepregs
 Especially with RTM and complex, thick geometries;
quality control - NDI
AMIF – Bari - Italy Sept. 18–19, 2014
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OOA: Compression moulding
Examples of work at
NLR:
 TS caps
 TP window frame
 Ongoing research
TS and TP materials
AMIF – Bari - Italy Sept. 18–19, 2014
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OOA: Compression Moulding
Work required
 Process control  guarantee minimally required
properties
 Linked: reduce scatter in mechanical properties
 Engineering: how to model random fibre
properties acurately, corresponding with observed
fibre distribution on moulded parts
 Quality control: NDI of complex shaped parts  CT
scan offers promising results, however, how to
relate observations to quality (mechanical
properties)?
AMIF – Bari - Italy Sept. 18–19, 2014
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Conclusions
 The field of composites is increasing rapidly:



A wide range of materials are available and
continuously being developed
And same for the processes and increasing level of
automation
Especially now that composites outside Aerospace
are getting at a same level
 Plenty of opportunity and possibility of using
composites
 This makes it a real challenge for companies to select
the right Materials & Processes...but also very
interesting!
AMIF – Bari - Italy Sept. 18–19, 2014
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AMIF – Bari - Italy Sept. 18–19, 2014