Low-Cost Fabrication of High-Temperature Polyimide Matrix Composites

Eltron Research, Inc.

Boulder, CO

Technology developed demonstrates a new hybrid method for fabrication of high-temperature carbon fiber reinforced polyimide matrix composites. The method combines aspects of resin transfer molding, resin infusion, and prepreg/autoclave techniques.

The process is suitable for construction of parts that are currently built by prepreg/autoclave methods, but offers more efficient use of materials and minimization of personnel exposure to potentially hazardous chemicals.

• Composite panels fabricated in the program exhibited very good quality. Void contents of <3% were routinely obtained, and some values of <1% were realized. Glass transition temperatures of approximately 280° to 320° C were measured for RP-46 composites.
• Suitability of the method was demonstrated by fabrication of panels using the Maverick Corp. (Cincinnati, OH) BIM-15S system.
• Mechanical properties of the composites were generally comparable to literature data on press-cured materials.
• Weight loss after 1,000 hours at 316° C in air was generally <10%, and in one case <3%.

• The new hybrid fabrication method is more efficient with regards to tooling, labor, material, and scrap costs.
• Potential commercial applications include any strength or stiffness critical structural components exposed to elevated temperatures. Aircraft applications include ducts, cowlings, and fairings subject to aerothernal or exhaust heating. Potential engine components include ducts, shrouds, and containment structures.

• Potential NASA applications of this technology include Reusable Launch Vehicle primary and secondary structures subject to aerothermal heating. These include intertank components, spars, ribs, skins, and stringers. Secondary structures such as ducts, cowlings, and fairings subject to aerothermal or exhaust heating are also appropriate.

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