SAMPE Journal - July/August 2011 - 54

LTM205 OOA Materials for Novel Prepreg Formats for Cauls and Tooling Manufactured from Very Low CTE CB1100 Ceramic Tooling Block
Levi S. Woods ATK Aerospace Structures, Clearfield, UT Email: Levi.Woods@atk.com Jon P. Grigson Advanced Composites Group, Inc., Tulsa, OK Abstract This article looks at the development by ATK and ACG of the LTM205 prepreg system for Out-of-Autoclave (OOA) caul tooling applications and its use with the low CTE CB1100 ceramic block and comparison with other master materials often employed. A brief overview will be presented on these materials along with formats employed to enable high-quality cauls to be manufactured for major aerospace tooling programs. In order to best understand the potential for these materials some brief manufacturing examples will be looked at and the performance to date examined. Introduction Alliant TechSystems, Inc. (ATK) was recently awarded a large contract to supply hat-shaped stiffeners and z-shaped frame structural components for a new composite commercial aircraft program. These structural parts range in length from less than 2 meters to 15 plus meters, with considerable variation across parts in degrees of part loft, twist, and local joggles. In addition to these design considerations, part thickness tolerance requirements defined by the customer were identified early on as a particular challenge. Satisfying these rigorous customer requirements became the subject of much attention during the development phase of the program. After thorough analysis by ATK, it was determined a caul would be employed to control precise laminate thickness and global tolerance requirements. The candidate materials would need to exhibit a low coefficient of thermal expansion (CTE), be cost-effective, and capable of repeatedly producing concession-free parts with an exceptional surface finish. A number of caul materials were compared and trialed during the project’s testing phase. One relatively new material, LTM205 from Advanced Composites Group, Inc. (ACG), was selected by ATK because of its unique capabilities and stable properties. With a fundamental requirement for a high tolerance caul, the master material chosen by ATK was the CB1100 from ACG. The CB1100 is a ceramic foam master material with a very low CTE, competitive price point, and is easily fabricated into a stable master for the LTM205 caul material. The selection of LTM205 and CB100 to meet the design and cost requirements of the program represents a significant step forward in the technology of OOA tooling materials for applications with rigorous tolerance demands. Both materials offer distinct advantages over typical products often used in industry when a cost effective material is needed to perform at a very high quality level. Similar to many engineered materials that are tailored to perform a specific function, attention to detail is critical and certain parameters may need to be adjusted to meet each program-specific requirement. Target specifications for future material development are therefore discussed along with future needs for the advancement of similar materials. Technical Challenges to Create a Concession Free Part The typical uses of a caul sheet are to control part outermold-line (OML) profile or generally control part thickness. However, with the ever-growing need to increase structural efficiency and fuel economy in commercial aerospace transportation, part thickness control is critical to ensure structural loads are carried efficiently and excess weight is eliminated in all areas of the aircraft. The customer requireSAMPE Journal, Volume 47, No. 4, July/August 2011

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SAMPE Journal - July/August 2011

Table of Contents for the Digital Edition of SAMPE Journal - July/August 2011

SAMPE Journal - July/August 2011
Contents
President’s Message
Technical Director’s Corner
Electrically-Heated Ceramic Composite Tooling for Out-of-Autoclave Manufacturing of Large Composite Structures
SAMPE 2011–A Review
SAMPE 2011 Photo Gallery
SAMPE Tech 2011 Conference
SAMPE Tech 2011 Exhibition
Europe News & Views
SAMPE Europe’s SETEC 2011, Leiden
SAMPE Europe’s SEICO 2012, Paris
SAMPE China 2011
12th Japan International SAMPE Symposium and Exhibition – JISSE-12
SAMPE Books & CD’s Order Form
SAMPE Proceedings
SAMPE Journal Editorial Calender
The SAMPE Foundation
Welcome SAMPE’s Newest Members
Rapid/Affordable Composite Tooling Strategies Utilizing Fused Deposition Modeling
Corporate Partners
Industry News
SAMPE 2012 Call for Papers
SAMPE 2012 Exhibition
Materials & Products
SAMPE Asia 2012|Kuala Lumpur, Malaysia
LTM205 OOA Materials for Novel Prepreg Formats for Cauls and Tooling Manufactured from Very Low CTE CB1100 Ceramic Tooling Block
Advertiser’s Index
Resource Center
SAMPE LinkedIn Communities
Industry Events Calendar
Chapter Meetings Dates and Contacts
SAMPE Journal - July/August 2011 - SAMPE Journal - July/August 2011
SAMPE Journal - July/August 2011 - Cover2
SAMPE Journal - July/August 2011 - Contents
SAMPE Journal - July/August 2011 - 2
SAMPE Journal - July/August 2011 - President’s Message
SAMPE Journal - July/August 2011 - 4
SAMPE Journal - July/August 2011 - Technical Director’s Corner
SAMPE Journal - July/August 2011 - Electrically-Heated Ceramic Composite Tooling for Out-of-Autoclave Manufacturing of Large Composite Structures
SAMPE Journal - July/August 2011 - 7
SAMPE Journal - July/August 2011 - 8
SAMPE Journal - July/August 2011 - 9
SAMPE Journal - July/August 2011 - 10
SAMPE Journal - July/August 2011 - 11
SAMPE Journal - July/August 2011 - 12
SAMPE Journal - July/August 2011 - 13
SAMPE Journal - July/August 2011 - 14
SAMPE Journal - July/August 2011 - 15
SAMPE Journal - July/August 2011 - SAMPE 2011–A Review
SAMPE Journal - July/August 2011 - SAMPE 2011 Photo Gallery
SAMPE Journal - July/August 2011 - SAMPE Tech 2011 Conference
SAMPE Journal - July/August 2011 - SAMPE Tech 2011 Exhibition
SAMPE Journal - July/August 2011 - Europe News & Views
SAMPE Journal - July/August 2011 - 21
SAMPE Journal - July/August 2011 - SAMPE Europe’s SETEC 2011, Leiden
SAMPE Journal - July/August 2011 - 23
SAMPE Journal - July/August 2011 - SAMPE Europe’s SEICO 2012, Paris
SAMPE Journal - July/August 2011 - 25
SAMPE Journal - July/August 2011 - SAMPE China 2011
SAMPE Journal - July/August 2011 - 27
SAMPE Journal - July/August 2011 - 12th Japan International SAMPE Symposium and Exhibition – JISSE-12
SAMPE Journal - July/August 2011 - SAMPE Books & CD’s Order Form
SAMPE Journal - July/August 2011 - SAMPE Proceedings
SAMPE Journal - July/August 2011 - 31
SAMPE Journal - July/August 2011 - SAMPE Journal Editorial Calender
SAMPE Journal - July/August 2011 - The SAMPE Foundation
SAMPE Journal - July/August 2011 - Welcome SAMPE’s Newest Members
SAMPE Journal - July/August 2011 - 35
SAMPE Journal - July/August 2011 - 36
SAMPE Journal - July/August 2011 - Rapid/Affordable Composite Tooling Strategies Utilizing Fused Deposition Modeling
SAMPE Journal - July/August 2011 - 38
SAMPE Journal - July/August 2011 - 39
SAMPE Journal - July/August 2011 - 40
SAMPE Journal - July/August 2011 - 41
SAMPE Journal - July/August 2011 - 42
SAMPE Journal - July/August 2011 - 43
SAMPE Journal - July/August 2011 - 44
SAMPE Journal - July/August 2011 - Corporate Partners
SAMPE Journal - July/August 2011 - Industry News
SAMPE Journal - July/August 2011 - 47
SAMPE Journal - July/August 2011 - SAMPE 2012 Call for Papers
SAMPE Journal - July/August 2011 - SAMPE 2012 Exhibition
SAMPE Journal - July/August 2011 - Materials & Products
SAMPE Journal - July/August 2011 - 51
SAMPE Journal - July/August 2011 - SAMPE Asia 2012|Kuala Lumpur, Malaysia
SAMPE Journal - July/August 2011 - 53
SAMPE Journal - July/August 2011 - LTM205 OOA Materials for Novel Prepreg Formats for Cauls and Tooling Manufactured from Very Low CTE CB1100 Ceramic Tooling Block
SAMPE Journal - July/August 2011 - 55
SAMPE Journal - July/August 2011 - 56
SAMPE Journal - July/August 2011 - 57
SAMPE Journal - July/August 2011 - 58
SAMPE Journal - July/August 2011 - 59
SAMPE Journal - July/August 2011 - 60
SAMPE Journal - July/August 2011 - 61
SAMPE Journal - July/August 2011 - Advertiser’s Index
SAMPE Journal - July/August 2011 - 63
SAMPE Journal - July/August 2011 - Resource Center
SAMPE Journal - July/August 2011 - 65
SAMPE Journal - July/August 2011 - 66
SAMPE Journal - July/August 2011 - 67
SAMPE Journal - July/August 2011 - 68
SAMPE Journal - July/August 2011 - 69
SAMPE Journal - July/August 2011 - 70
SAMPE Journal - July/August 2011 - SAMPE LinkedIn Communities
SAMPE Journal - July/August 2011 - Chapter Meetings Dates and Contacts
SAMPE Journal - July/August 2011 - Cover3
SAMPE Journal - July/August 2011 - Cover4
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