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Carbon Tape Material Specification

Carbon Tape Material Specification. 2.4 (11) - Who surveys and approves PCD, and who is authorized to change it? 2.4 (12) - “If equivalency is not demonstrated, the prepreg production process change will not be allowed.” Engineering Judgment? Application?

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Carbon Tape Material Specification

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  1. Carbon Tape Material Specification • 2.4 (11) - Who surveys and approves PCD, and who is authorized to change it? • 2.4 (12) - “If equivalency is not demonstrated, the prepreg production process change will not be allowed.” Engineering Judgment? Application? • 2.4 - How does potential user find work in progress? August 6 - 8, 2002

  2. Carbon Tape Material Specification • 4.0 (17) - SACMA specification mechanism for revision? • 5.0 (17) - Same quality criteria for all users/application? • 6.0 (18) - PCD must be developed, available, and referenced by revision • 6.1 (18) - Out-time by shelf life could be tied to N batch reviews. August 6 - 8, 2002

  3. Carbon Tape Material Specification • Table 1 (20) - Standard exposure conditions for moisture conditioning? Thermal induced microcracking - spiking? • 6.2.1 (21) - Experiment assumes level of control which makes tighter limits possible • 6.2.2 (22) - Purchasing document other than mat’l spec for roll characteristics? • 6.3.1 (34) - Baseline cure - oven or AC? NDT? August 6 - 8, 2002

  4. Carbon Tape Material Specification • Table 5 (26) - Rec’d thickness for crossplied laminates rounded to 0.100” (balanced/sym.) • 6.3.3 (27) - Exposure temps for fluids? • Table 6b (29) - Cocure vs. sec. bonded skins • Table 7 (30) - Runout # cycles? • 9.1 (36) - Supplier demonstrates testing, records, calibration, SPC to whom? • 9.4.1 (37) - Purchaser notified of retesting August 6 - 8, 2002

  5. Carbon Tape Material Specification • Appendix A - Future Needs -Improved methods for ID of sources of variability in composite materials(nested experimental designs) August 6 - 8, 2002

  6. 250 &350°F Cure Epoxy Prepregs C - tape(s), PW, 5H, 8H G - tape(s), 120, 7781 A - 285 Other composites Phenolic Polyester Wet Layups - Dry Fabrics Adhesives 250 & 350°F Film Adhesives Paste Adhesives Foaming Adhesive Potting Material Core H/C - cell size(s), density(s) Foam - Density(s), Temps Surfacing film Larger Scope of Composite Materials August 6 - 8, 2002

  7. Carbon Tape Process Specification • 1.2 (10) - “safe’ in both docs, context depends on application • Material document says min. 3 batches (10), process document says 3 to 5 (12) • 1.3 (12) - Fabricator qual tests consist of? Tying in qualification with other cure cycles and fabrication methods? August 6 - 8, 2002

  8. Material vs. Process Specifications • Most material specifications reference testing or other industry documents • Most process spec referenced documents are internal 2nd and 3rd tier process specs • Scope of all fabrication processes seems ambitious • Suggest example spec should be for panel processing August 6 - 8, 2002

  9. Composite Rotor Blade EPB (25) Material Specs G Tapes/Fabrics C Tapes/Fabric Film Adhesive Honeycomb Foaming Adh. Paste Adhesive Sealants Surfacing Film Consumables Process Specs Comp Fab - Prim (70+) H/C Bond Prep (24+) Composite Inspect (16) Inspect Criteria (26+) Ultrasonic (23+) Radiographic (23) Bondline (12) Paste Bond (21) Serialization Degreasing Process Specs Cont’d Film Bond (29) Clean Room (11) Trim/Drill/Mach (44) EPB Finish Contour August 6 - 8, 2002

  10. Composite Fabrication Specification • Closed Cell Core Detail Fab (20) • H/C Core Detail Fab (26) • Shelf Life, Out-time (22) • Secondary Structure (52) • Autoclave/Oven/Press Thermal Survey (13) • Part ID August 6 - 8, 2002

  11. Composite Fabrication SpecificationCure Cycle Variations • Material - 250 and 350°F cure • Tooling - Composite, matched metal, internally pressurized • Process - Hand layup, resin injection • Structure - Solid laminate, sandwich (Foam/HC, precured/cobonded skins) • Cure Vessel - Autoclave, oven, press, trapped rubber August 6 - 8, 2002

  12. Film Adhesive Bonding • Composite surface preparation • Bond primer application (20) • Metal Surface Preparations • Al Anodize (23) • Titanium (21+) • AM355 Steel (37) • Ni/CRES (22) • Ferrous (18) August 6 - 8, 2002

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