THERMOPLASTIC IN SITU FIBER PLACEMENT FOR FUTURE SOLID ROCKET MOTOR CASINGS MANUFACTURING

摘要

The main goal of the presented research was to enhance the Thermoplastic Automated Fiber Placement process towards industrial production of aerospace parts. Detailed process and hardware optimization of an AFPT GmbH placement head was performed with the main goal to establish a stable, robust process with optimized laminate quality. In situ consolidated laminates showed high mechanical properties with an increase in tensile strength of approximately 20% compared to press-consolidated laminates. Recorded process data highlighted the capability of the closed loop process control and of the hardware components to compensate tolerances of the raw material or the tooling. To demonstrate the process stability coupon test results and recorded temperature data during manufacturing were analyzed. Thermoplastic Automated Fiber Placement's technology readiness was demonstrated by manufacturing a 2.5 m long booster segment with 1.3 m in diameter.