Project Title:

Development of Synergistic Prepregging Technologies

04.06-3200
902079
Development of Synergistic Prepregging Technologies

Abstract:

High performance, thermoplastic (TP) resins are notoriously difficult to melt-prepreg
because of their high viscosities, and high modulus fibers for advanced composites
are difficult to handle and melt-prepreg. Two innovative prepregging technologies
will be combined with advanced fiber/matrix materials to form prepregs that provide
superior structural efficiency and excellent high temperature performance. These
synergistic technologies are high shear prepregging (HSP) and maximal fiber spreading
(MFS). HSP technology dramatically reduces TP resin viscosities by shear-thinning
and readily accomplishes complete fiber impregnation. Current commercial prepregging
technology yields prepregs with minimum fiber areal weights (FAWs) of only 90 g/m2.
Foster-Miller's MFS technology will be able to achieve FAWs of 30 g/m2. Combining
these two technologies will result in ultrathin, high performance thermoplastic prepreg
which will provide significant structural weight savings and enhanced performance
in aerospace applications. This Phase I effort will demonstrate the synergistic prepregging
technologies by designing and fabricating a small-scale demonstration MFS system
which will be used in conjunction with HSP technology to produce high quality Gr/LaRC-TPI
prepreg with a FAW <35 g/m2. This prepreg will be molded into laminates for SEM,
tensile testing, and sampling to NASA.
Ultrathin (l mil thickness), high performance TP prepreg can be used with automated
fabrication methods to make aerostructure components for commercial applications
like the high speed civil transport, tubular members for space structures, and ultralightweight
beam structures.
thermoplastic, fiber spreading, LaRC-TPI, graphite fiber, advanced composites, high
temperature performance, lightweight structures