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At least 19 records

All sources NASA NTRS DOE OSTI

NASA NTRS1993

A new NASA LaRC Multi-Purpose Prepregging Unit

A multi-purpose prepregging machine has been designed and built for NASA Langley Research Center. The machine has numerous advantages over existing units due to its various modular components. Each of these can be used individually or simultaneously depending on the required prepregging method. A reverse roll coater provides the ability to prepare thin films from typical hot-melt thermoset formulations. Also, if necessary, the design allows direct fiber impregnation within the reverse roll coater gap. Included in the impregnation module is a solution dip tank allowing the fabrication of thermoplastic prepregs from solution. The proceeding modules within the unit consist of four nip stations, two hot-plates, a hot-sled option and a high temperature oven. This paper describes the advantages of such a modular construction and discusses the various processing combinations available to the prepregger. A variety of high performance prepreg material systems were produced on IM7 (Hercules) carbon fiber. These included LaRC RP46, a PMR-type resin processed from methanol and two polyamide acids, LaRC IA and LaRC ITPI, prpregged from N-methyl pyrrolidinone (NMP). Parameters involved in the production of these prepreg materials are presented as are the mechanical properties of the resulting good quality laminates. A brief introduction into the existing prepregging science is presented. Topics relating to solution prepregging are identified with a focus on the current research effort and its future development.

Wilkinson, S. P.↗

NASA NTRS1982

PMR-15 polyimide modifications for improved prepreg tack

The use of mixed solvents and of modified monomeric ester reactants was investigated as a means of improving the tack and drape retention characteristics of PMR-15 polyimide prepreg. Methanol, ethanol, 1-propanol and 1-butanol were used to prepare the esters, prepreg solutions, and T-300 graphite fabric and Celion 6000 unidirectional fiber prepregs. The tack retention characteristics of the T-300 fabric prepreg after exposure to simulated use conditions were determined using a simple lap shear test. Drape was qualitatively assessed by visually monitoring the deformability of the prepreg. Thermo-oxidative stability and mechanical properties retention of the Celion 6000 grahite fiber composites were determined as a function of exposure time in air at 600 F.

Vannucci, R. D.↗

NASA NTRS1985

Characterization of Polyimide Matrix Resins and Prepregs

Graphite/polyimide composite materials are attractive candidates for a wide range of aerospace applications. They have many of the virtues of graphite/epoxies, i.e., high specific strengths and stiffness, and also outstanding thermal/oxidative stability. Yet they are not widely used in the aerospace industry due to problems of procesability. By their nature, modern addition polyimide (PI) resins and prepregs are more complex than epoxies; the key to processing lies in characterizing and understanding the materials. Chemical and rheological characterizations are carried out on several addition polyimide resins and graphite reinforced prepregs, including those based on PMR-15, LARC 160 (AP 22), LARC 160 (Curithane 103) and V378A. The use of a high range torque transducer with a Rheometrics mechanical spectrometer allows rheological data to be generated on prepreg materials as well as neat resins. The use of prepreg samples instead of neat resins eliminates the need for preimidization of the samples and the data correlates well with processing behavior found in the shop. Rheological characterization of the resins and prepregs finds significant differences not readily detected by conventional chemical characterization techniques.

Maximovich, M. G.↗

NASA NTRS2019

Characterization of Prepreg Tack for Composite Manufacturing by Automated Fiber Placement

Automated fiber placement (AFP) has become the industry standard for large-scale production of carbon fiber reinforced plastics (CFRP) to improve rate and reduce defects associated with manual layup. Still, defects generated during AFP processes require manual, painstaking inspection by technicians and rework of the part when substantial defects are found. Prepreg (carbon fiber infused with uncured epoxy resin) tack is one of the primary factors that influences the generation of defects that arise during auto-mated fiber placement (AFP). Tack, as it relates to AFP processes and defect formation, can be understood as a combination of two stages, cohesion and decohesion. During the cohesion phase, two pieces of prepreg are brought into contact under elevated temperature and pressure. Compaction of the resin within the contact area will result in a degree of intimate contact, I, between the mating prepreg surfaces. Defect formation, as a result of decohesion between prepreg surfaces, occurs after the cohesion phase and arises due to stress from events such as fiber placement over an existing defect, on a contoured path, etc. (Figure 1). Tack strength resists the displacement of prepreg on a surface due to stresses developed during deposition.

Wohl, Christopher J↗

DOE OSTI2026

Siloxane-modified polycarbosilane flexible Prepregs for fabrication of ceramic matrix composites via compression molding and PIP densification

For this work, the development of ceramic matrix composites (CMCs) using 5 harness satin carbon fiber fabric impregnated with commercial polycarbosilane precursor plasticized by siloxane copolymer was investigated aiming to improve wetting behavior and shape conformability. The polycarbosilane precursor and polysiloxane plasticizer were mixed at varying weight ratios to obtain flexible preceramic resin prepreg cloths. 13 plies of preceramic polymer prepreg cloths were stacked in 0/90° layup and cured by compression molding, followed by densified via PIP process. The CMCs were densified with eight PIP cycles followed by final crystallization at 1600 °C. The CMCs made with 10 wt% polysiloxane loading showed lower viscosity of the prepreg resin as well as higher strength and displacement to failure compared to those fabricated from unplasticized polycarbosilane prepolymer. In contrast, at higher concentration of plasticizer, viscosity of the prepreg resin increased, and the CMC became more brittle; however, it exhibited considerably higher thermal conductivity.

Carbosilane↗

NASA NTRS1976

PMR polyimide prepreg with improved tack characteristics

Current PMR Polyimide prepreg technology utilizes methanol or ethanol solvents for preparation of the PMR prepreg solutions. The volatility of these solvents limits the tack and drape retention characteristics of unprotected prepreg exposed to ambient conditions. Studies conducted to achieve PMR 15 Polyimide prepreg with improved tack and drape characteristics were described. Improved tack and drape retention were obtained by incorporation of an additional monomer. The effects of various levels of the added monomer on the thermo-oxidative stability and mechanical properties of graphite fiber reinforced PMR 15 composites exposed and tested at 316 C (600 F) were discussed.

Serafini, T. T.↗

NASA NTRS1978

PMR Polyimide prepreg with improved tack characteristics

Current PMR Polyimide prepreg technology utilizes methanol or ethanol solvents for preparation of the PMR prepreg solutions. The volatility of these solvents limits the tack and drape retention characteristics of unprotected prepreg exposed to ambient conditions. Studies conducted to achieve PMR 15 Polyimide prepreg with improved tack and drape characteristics are described. Improved tack and drape retention were obtained by incorporation of an additional monomer. The effects of various levels of the added monomer on the thermo-oxidative stability and mechanical properties of graphite fiber reinforced PMR 15 composites exposed and tested at 316 C (600 F) are discussed.

Serafini, T. T.↗

NASA NTRS1995

Apparatus for consolidating a pre-impregnated, filament-reinforced polymeric prepreg material

An apparatus and method were developed for providing a uniform, consolidated, unidirectional, continuous, fiber-reinforced polymeric material. The apparatus comprises a supply means, a forming means, a shaping means, and a take-up means. The forming means further comprises a pre-melting chamber and a stationary bar assembly. The shaping means is a loaded cooled nip-roller apparatus. Forming takes place by heating a polymeric prepreg material to a temperature where the polymer becomes viscous and applying pressure gradients at separate locations along the prepreg material. Upon exiting the forming means, the polymeric prepreg material is malleable, consolidated, and flattened. Shaping takes place by passing the malleable, consolidated, flattened prepreg material through a shaped, matched groove in a loaded, cooled nip-roller apparatus to provide the final solid product.

Sandusky, Donald A.↗

NASA NTRS1995

Multipurpose Prepregging Machine

Machine designed and built for variety of uses involving coating or impregnating ("prepregging") fibers, tows, yarns, or webs or tapes made of such fibrous materials with thermoplastic or thermosetting resins. Prepreg materials produced used to make matrix/fiber composite materials. Comprises modules operated individually, sequentially, or simultaneously, depending on nature of specific prepreg material and prepregging technique used. Machine incorporates number of safety features.

Johnston, N. J.↗

NASA NTRS2003

Studies on Hot-Melt Prepregging of PMR-II-50 Polyimide Resin with Graphite Fibers

A Second generation PMR (in situ Polymerization of Monomer Reactants) polyimide resin, PMR-II-50, has been considered for high temperature and high stiffness space propulsion composites applications for its improved high temperature performance. As part of composite processing optimization, two commercial prepregging methods: solution vs. hot-melt processes were investigated with M40J fabrics from Toray. In a previous study a systematic chemical, physical, thermal and mechanical characterization of these composites indicated that poor resin-fiber interfacial wetting, especially for the hot-melt process, resulted in poor composite quality. In order to improve the interfacial wetting, optimization of the resin viscosity and process variables were attempted in a commercial hot-melt prepregging line. In addition to presenting the results from the prepreg quality optimization trials, the combined effects of the prepregging method and two different composite cure methods, i.e., hot press vs. autoclave on composite quality and properties are discussed.

Shin, E. Eugene↗

NASA NTRS2004

Studies on Hot-Melt Prepregging on PRM-II-50 Polyimide Resin with Graphite Fibers

A second generation PMR (in situ Polymerization of Monomer Reactants) polyimide resin PMR-II-50, has been considered for high temperature and high stiffness space propulsion composites applications for its improved high temperature performance. As part of composite processing optimization, two commercial prepregging methods: solution vs. hot-melt processes were investigated with M40J fabrics from Toray. In a previous study a systematic chemical, physical, thermal and mechanical characterization of these composites indicated the poor resin-fiber interfacial wetting, especially for the hot-melt process, resulted in poor composite quality. In order to improve the interfacial wetting, optimization of the resin viscosity and process variables were attempted in a commercial hot-melt prepregging line. In addition to presenting the results from the prepreg quality optimization trials, the combined effects of the prepregging method and two different composite cure methods, i.e. hot press vs. autoclave on composite quality and properties are discussed.

Shin, E. Eugene↗

NASA NTRS1981

The industrial processing of unidirectional fiber prepregs

Progress made in the industrial processing of preimpregnated composites with unidirectional fibers is discussed, with particular emphasis on applications within the aerospace industry. Selection of industrial materials is considered. Attention is given to the conditions justifying the use of composites and the properties required of industrial prepregs. The hardening cycle is examined for the cases of nonmodified and polymer modified resins, with attention given to the stabilization of flow, the necessary changes of state, viscosity control, and the elimination of porosity. The tooling necessary for the fabrication of a laminated plate is illustrated, and the influence of fabrication and prepreg properties on the mechanical characteristics of a laminate are indicated. Finally, the types of prepregs available and the processing procedures necessary for them are summarized.

Laird, B.↗

NASA NTRS1982

Development of quality assurance methods for epoxy graphite prepreg

Quality assurance methods for graphite epoxy/prepregs were developed. Liquid chromatography, differential scanning calorimetry, and gel permeation chromatography were investigated. These methods were applied to a second prepreg system. The resin matrix formulation was correlated with mechanical properties. Dynamic mechanical analysis and fracture toughness methods were investigated. The chromatography and calorimetry techniques were all successfully developed as quality assurance methods for graphite epoxy prepregs. The liquid chromatography method was the most sensitive to changes in resin formulation. The were also successfully applied to the second prepreg system.

Chen, J. S.↗

NASA NTRS1984

A theoretical study of resin flows for thermosetting materials during prepreg processing

A flow model which describes the process of resin consolidation during prepreg lamination was developed. The salient features of model predictions were explored. It is assumed that resin flows in all directions originate from squeezing action between two approaching adjacent fiber/fabric layers. In the horizontal direction, a squeezing flow between two nonporous parallel plates is analyzed, while in the vertical direction a poiseuille type pressure flow through porous media is assumed. Proper force and mass balance was established for the whole system which is composed of these two types of flow. A flow parameter, CF, shows to be a measure of processibility for the curing resin. For a given external load-F the responses of resin flow during prepreg lamination, as measured by CF, are categorized into three regions: (1) the low CF region where resin flows are inhibited by the high chemoviscosity during initial curing stages; (2) the median CF region where resin flows are properly controllable; and (3) the high CF region where resin flows are ceased due to fiber/fabric compression effects. Resin losses in both directions are calculated. Potential uses of this model and quality control of incoming prepreg material are discussed.

Hou, T. H.↗

NASA NTRS1984

Prepreg cure monitoring using diffuse reflectance-FTIR

An in situ diffuse reflectance-Fourier transform infrared technique was developed to determine infrared spectra of graphite fiber prepregs as they were being cured. A bismaleimide, an epoxy, and addition polyimide matrix resin prepregs were studied. An experimental polyimide adhesive was also examined. Samples were positioned on a small heater at the focal point of diffuse reflectance optics and programmed at 15 F/min while FTIR spectra were being scanned, averaged, and stored. An analysis of the resulting spectra provided basic insights into changes in matrix resin molecular structure which accompanied reactions such as imidization and crosslinking. An endo-exothermal isomerization involving reactive end-caps was confirmed for the addition polyimide prepregs. The results of this study contribute to a fundamental understanding of the processing of composites and adhesives. Such understanding will promote the development of more efficient cure cycles.

Young, P. R.↗

NASA NTRS1985

Properties of autoclaved Gr/PI composites made from improved tack PMR-15 prepreg

Autoclave processing studies were conducted, using improved tack PMR-15 prepreg, to determine the effect of tack enhancing PMR resin modifications on composite processability and mechanical properties. Improved tack graphite fiber reinforced PMR-15 prepregs were prepared and exposed to ambient conditions for various times and then autoclave molded into composites. Composite specimens were prepared and tested for flexural and interlaminar shear strengths at room temperature and 316 C. The retention of flexural and interlaminar shear strength as a function of exposure in air at 316 C was also determined. The results show that the modified PMR resin solutions provide prepreg with improved tack and drape retention characteristics without adversely affecting processability or mechanical properties of autoclave molded graphite fiber reinforced PMR-15 composites.

Vannucci, R. D.↗

NASA NTRS1985

Fracture characteristics of angleplied laminates fabricated from overaged graphite/epoxy prepreg

A series of angleplied graphite/epoxy laminates was fabricated from overaged prepreg and tested in tension to investigate the effects of overaged or advanced cure material on the degradation of laminate strength. Results, which include fracture stresses, indicate a severe degradation in strength. In addition, the fracture surfaces and microstructural characteristics are distinctly unlike any features observed in previous tests of this prepreg and laminate configuration. Photographs of the surfaces and microstructures reveal flat morphologies consisting of alternate rows of fibers and hackles. These fracture surface characteristics are independent of the laminate configurations. The photomicrographs are presented and compared with data from similar studies to show the unique characteristics produced by the overage prepreg. Analytical studies produced results which agreed with those from the experimental investigations.

Ginty, C. A.↗

NASA NTRS1987

Fracture characteristics of angleplied laminates fabricated from overaged graphite/epoxy prepreg

Ginty, Carol A.↗