Thermoplastic Composite Lunar Tower Truss Structure: Design Development and Verification
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Thermoplastics↗
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Results for “Thermoplastic composites”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Progressive Damage and Failure Analysis of Thermoplastic Composites in Low Velocity Impact Using MAT299
As part of the NASA Hi-Rate Composite Aircraft Manufacturing (HiCAM) Project, state-of-the-art progressive damage and failure analysis (PDFA) tools developed for use with thermosets are being evaluated for use in modeling alternative material systems, like thermoplastics. Experimental low-velocity impact data of a thermoplastic material system, AS4D/PEKK-FC, is presented and includes characterization of the impact damage mechanisms as well as associated load and displacement data. Following the presentation of experimental results, two simulation approaches using the PDFA tool MAT299 in the commercial off-the-shelf finite element software LS-DYNA are employed to predict damage area and force-displacement responses of thermoplastic panels subjected to various impact energies. The first modeling method uses solid elements with a high-density mesh and a ply-by-ply modeling approach similar to previously published work for thermosets. This method has the capability of capturing individual crack development, progression, and delamination on a per ply basis. The second modeling method uses TSHELL elements that have in-plane dimensions that are an order of magnitude larger than the elements used in the solid element approach and reduces the number of elements through the thickness of the laminate. The second method produces a lower-fidelity model with reduced run times that is incapable of monitoring every delamination plane and damage within each ply. Results from both simulation methods are compared to experiment, and limitations of the methods are discussed.
Composite material↗
Progressive Damage and Failure Analysis of Thermoplastic Composites in Low Velocity Impact Using MAT299
As part of the NASA Hi-Rate Composite Aircraft Manufacturing (HiCAM) Project, state-of-the-art progressive damage and failure analysis (PDFA) tools developed for use with thermosets are being evaluated for use in modeling alternative material systems, like thermoplastics. Experimental low-velocity impact data of a thermoplastic material system, AS4D/PEKK-FC, is presented and includes characterization of the impact damage mechanisms as well as associated load and displacement data. Following the presentation of experimental results, two simulation approaches using the PDFA tool MAT299 in the commercial off-the-shelf finite element software LS-DYNA are employed to predict damage area and force-displacement responses of thermoplastic panels subjected to various impact energies. The first modeling method uses solid elements with a high-density mesh and a ply-by-ply modeling approach similar to previously published work for thermosets. This method has the capability of capturing individual crack development, progression, and delamination on a per ply basis. The second modeling method uses TSHELL elements that have in-plane dimensions that are an order of magnitude larger than the elements used in the solid element approach and reduces the number of elements through the thickness of the laminate. The second method produces a lower-fidelity model with reduced run times that is incapable of monitoring every delamination plane and damage within each ply. Results from both simulation methods are compared to experiment, and limitations of the methods are discussed.
Composite material↗
Resistance Welding Simulation of a Thermoplastic Composite Lap Shear Coupon
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Crystallization kinetics↗
High Energy Dynamic Impact Testing of APC AS4/PEKK-FC and TC1225 LMPAEK T700G Thermoplastic Composite Materials
High energy dynamic impact tests were conducted on Solvay APC AS4D/PEKK-FC and Toray TC1225 LMPAEK T700Gthermoplastic composite laminates. The primary objective was to provide data for evaluation of computational composite impact models. Empirical results indicate an approximately 50% increase in penetration threshold velocity and over 100% increase in penetration energy threshold for the TC1225 LMPAEK T700Gcomposite compared to the APC AS4D/PEKK-FC composite. The velocity required to produce NDE-detectable delamination in the TC1225 LMPAEK T700Gcomposite was roughly twice that for the APC AS4D/PEKK-FC composite. Comparison of the normalized energy absorption showed similar results for the APC AS4D/PEKK-FC system compared to a previously studied IM7/8552 composite material. The TC1225 LMPAEK T700Gsystem absorbed approximately twice that of the other two systems when normalized by areal weight.
Impact↗
Ballistic characterization of additively manufactured extrusion deposited thermoplastic composite plates
Additive manufacturing (AM) is rapidly emerging in high performance applications such as army ground vehicles, automotive and transportation. However, the response of AM parts/components to extreme loading such as high velocity impacts is less studied. In this work, the performance under ballistic impact of AM panels is evaluated using a medium velocity gas gun, generating projectile velocities up to 400 m/s. The preferential print orientation properties are considered in order to evaluate whether the panels exhibit isotropic or anisotropic behavior under impact. Surface morphology is investigated by milling the beads smooth on samples and comparing the impact on as-printed samples to those that are smoothed. The effect of nickel chromium micron (nichrome) wire embedded in the AM panels (during print) of polycarbonate-carbon fiber (PC-CF) and polycarbonate-glass fiber (PC-GF) are explored. Thermoplastic polyurethane-acrylonitrile butadiene styrene/carbon fiber (TPU-ABS/CF), Acrylonitrile butadiene styrene-carbon-fiber (ABS-CF) AM samples absorbed >50% of the impact energy. The ballistic performance was noted to be in the following order – ABS-CF > TPU-ABS/CF > PC. Scanning electron microscopy (SEM) was conducted to study the interface between the nichrome wire and the polymer-fiber matrix. This work is the first of its kind exploring into the capabilities of AM panels as ballistic materials. This study leads the way for developing AM panels that are easily manufactured and exhibit superior ballistic resistance.
Landrie, Dakota M.↗
Ultralow-binder-content thermoplastic composites based on lunar soil simulant
Not Available
Oh, Kiwon↗
Numerical framework for integrated additive manufacturing-compression molding (AM-CM) of thermoplastic composites
Additive manufacturing-compression molding (AM-CM) has emerged as a transformative technology in advanced composite manufacturing. Additive manufacturing (AM) offers high design flexibility and the ability to produce complex geometries with precisely aligned fibers in the preferred orientation. Compression molding (CM) enhances composite materials by providing excellent dimensional stability, reduced porosity, high production rates, and a smooth surface finish. Despite these advantages, extensive integrated analysis is required to optimize processing conditions for improved fiber orientation distribution (FOD) and porosity control. Here, this study develops a comprehensive numerical model to simulate the AM-CM manufacturing process. The model isolates the effects of both the AM and CM phases while also capturing their integration. Additionally, it accounts for heat transfer, temperature-dependent viscosity, and fiber orientation in the extruded fiber-filled polymer, accurately representing material behavior during processing. This approach enables the analysis of interactions between deposited beads of complex strand shapes and their interface regions after full compression. Moreover, the model predicts key parameters such as polymer flowability, fiber orientation, and temperature evolution in AM-CM parts. By optimizing processing conditions, it facilitates a controlled and predictable microstructure.
36 MATERIALS SCIENCE↗
Damage propagation in short fiber thermoplastic composites analyzed through coupled 3D experiments and simulations
Not Available
Hanhan, Imad (ORCID:0000000339315117)↗
Toward a circular economy: zero-waste manufacturing of carbon fiber-reinforced thermoplastic composites
Fiber-reinforced composites are becoming ubiquitous as a way of lightweighting in the wind, aerospace, and automotive industries, but current recycling technologies fall short of a circular economy. In this work, fiber-reinforced composites made of recycled carbon fiber and polyphenylene sulfide were recycled and remanufactured using common processing technologies such as compression and injection molding. An industrially viable size-exclusive sieving technique was used to retain fiber length and reduce variability in the mechanical properties of the remanufactured composites. Fiber length reduction alone could not explain the strength reductions apparent in the composites, which we propose are due to microstructural inhomogeneity as defined by poor dispersion of the fibers. Future recycling efforts must focus on fiber length retention and good dispersion to make composite remanufacturing a viable path toward a circular economy.
36 MATERIALS SCIENCE↗
Oak Ridge National Laboratory Thermoplastic Composite Joining of Pultruded Continuous Fiber Spars for Multi-Functional Battery Enclosure
Oak Ridge National Laboratory (ORNL) worked with DowAksa Industry to investigate the potential of using PA66 material to produce larger composite parts, transcending the limitations of traditional presses. The project aimed to develop a suitable material for printing battery boxes using Nylon 66 infused with 40 wt.% carbon fiber, compatible with the ORNL Additive Manufacturing and Compression Molding (AM-CM) system. However, even with extensive work, it was concluded that the material is not compatible with the AMCM process and suitable for joining using compression technique. Main reason for the incompatibility were found to be very high crystallinity of the PA66 grade chosen for this work. To improve printability, a modifier (proprietary) was added to decrease crystallinity, but this led to reduced thermal stability and adhesion issues.
36 MATERIALS SCIENCE↗
Development of an impact- and solvent-resistant thermoplastic composite matrix
Synthesis, moldability and chloroform, acetone and tricresyl phosphate resistance of 16 polymer compositions are described. These aliphatic heterocyclic polymers include polyimides, polybenzimidazoles, and N-arylenepolybenzimidazoles. A solution condensation (cresol) method to prepare imidized aliphaic polyimides is described. Two polyimides and one polybenzimidazole demonstrate no crazing or cracking during 500 hr exposure to the cited solvents under stress. Modification of one aliphatic polyimide with several aromatic amines suggests that m-phenylenediamine is singular in its behavior to improve the chloroform resistance of that class of polyimides.
Delano, C. B.↗
Estimation of crystallinity in a model thermoplastic composite
Crystallinities as low as 16 percent have been estimated by determination of the interplanar spacing on PET/carbonaceous filament composites with resin content of aobut 25 percent w/w using wide-angle X-ray scattering (WAXS) in the angular range 2 theta = 16-18 deg. The diffraction pattern of the carbonaceous reinforcements masks the major reflections of the resin, and the resin content and the crystallinity are kept low to make the simulation reasonable.
Wakelyn, N. T.↗
Resolution of wide-angle X-ray scattering from a thermoplastic composite
Wide-angle X-ray scattering from a polyetheretherketone/carbonaceous-fiber composite has been resolved using a curve-fit procedure. This resolution yielded under-curve areas for crystalline, amorphous, and fiber scatter which could be used as the basis for an estimation of crystallinity.
Wakelyn, N. T.↗
Fatigue delamination behavior of PEEK thermoplastic composite laminates
The delamination resistance of graphite-reinforced PEEK composites was quantified by conducting static and cyclic edge delamination tests on (35n/-35n/0n/90n)s AS4/PEEK laminates, where n = 1, 2. The experimentally determined mechanical delamination onset strains were used to calculate the critical strain-energy release rate for delamination onset as a function of fatigue cycle. The delamination onset strains decreased dramatically with fatigue cycles and then began to level off to an endurance limit at 1 million cycles. Although the static interlaminar fracture toughness of the AS4/PEEK composite is much greater than the toughness of graphite epoxy composites, the delamination fatigue threshold, calculated from the cyclic strain endurance limit at 1 million cycles, was only slightly greater than the threshold for graphite epoxy composites. The contribution of residual thermal stresses to delamination in the AS4/PEEK is substantial due to the large temperature range between the manufacture and the room temperatures.
O'Brien, T. K.↗
Resolution of wide angle X-ray scattering from a thermoplastic composite
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Wakelyn, N. T.↗