SAMPE Journal - September/October 2013 - (Page 5)

A Note from the Technical DirecTor Dr. Scott W. Beckwith SAMPE Journal Technical Editor swbeckwith@aol.com Automated Fiber Placement, Robotics, Out-of-Autoclave Thermosets, Thermoplastics – Technologies Making Significant Advances in Aerospace Applications The two lead articles in this issue of the SAMPE Journal highlight significant game-changing advances in materials and process engineering technologies on several fronts which have been in development over the past few years. We have seen a lot of technical papers, presentations and panels at SAMPE conferences on the subjects noted above – all with increased frequency. SAMPE has always been about bringing new technologies out of the laboratory and into the world of practical applications. NASA contracted The Boeing Company, who along with Janicki Industries (tooling), fabricated a large cryogenic tank using automated fiber placement/robotics and an out-of-autoclave thermoset resin/ carbon fiber system. Traditionally, large pressure vessels such as the old Hercules Aerospace Filament Wound Case (FWC) Space Shuttle booster cases were filament wound using traditional thermoset wet-winding resins and oven cure technology (at 3.7m/146-inch diameter). In the NASA technology program presented in the first Featured Article, an out-of-autoclave Cytec 5320-1/Hexcel IM7 system was used with tape materials having 70 and 145 g/m2 (gsm) weight lightweight materials in order to counteract cryogenic permeability issues. The tank was then successfully tested for 20 pressure cycles at a temperature of -423°F/-253°C from 0 to 135 psi. Robotics also has been playing a significant role with thermoplastic materials in commercial aircraft structures where the emphasis on manufacturing “large” structures has been with us for some time as well. EADS France Innovation Works has been hard at work advancing such technologies as evidence in the second feature article. Thermoplastic resin technology advances have been making significant in-roads with thermoforming, compression molding, tape laying, filament winding and numerous other manufacturing processes for many years. Processing equipment has advanced in software and lay-down technology. Also of interest was the addition of lightning strike materials to the fabricated structure along the way. The Cytec APC2/Hexcel AS4 system has been well-characterized over the years as a pathfinder thermoplastic material with an excellent track record. The application of both the thermoplastic materials and robotics fiber placement continues to demonstrate that large structures can be efficiently made using both materials and process technology. Composite structures and applications will continue to push the envelope on size, complexity and dimension for applications yet to be considered. The current NASA cryogenic tank, for example at its current 2.4m diameter, is only the precursor for the upcoming 5.5m next generation which will be tested in early 2014. However, it too is the precursor for an 8.4m/27.5-ft diameter cryogenic tank planned to replicate today’s large launch vehicle structures which often use Aluminum or Aluminum-Lithium materials. Hence, process engineering advances continue forward, solving problems generated only in the near distant past. SAMPE Journal, Volume 49, No. 5, September/October 2013 5

Table of Contents for the Digital Edition of SAMPE Journal - September/October 2013

SAMPE Journal - September/October 2013
Contents
President’s Message
Technical Director’s Corner
Manufacturing Overview of a 2.4 Meter (7.9 Foot) Composite Cryotank
Welcome SAMPE’s Newest Members
SAMPE Proceedings
Corporate Partners
SAMPE On-Site Training Seminars
CAMX–The Composites and Advanced Materials Expo
Europe News & Views
SAMPE Europe’s SETEC 13 Wuppertal, Germany
Tech Tidbits
Thermoplastic Composites Technologies for Manufacturing Nose Fuselage Structures
Materials & Products
SAMPE Tech 2013|Wichita, KS
Perspectives
High Temperature RTM370 Polyimide Composites Fabricated by RTM: Characterization and Impact Testing
The SAMPE Foundation
SAMPE Tech 2014|Call for Papers
Industry News
Advertiser’s Index
SAMPE Journal Editorial Calender
Resource Center
Membership Application
SAMPE Proceedings Order Form
Industry Events Calendar
Chapter Contacts

SAMPE Journal - September/October 2013