Celion/Larc-160 graphite/polyimide composite processing techniques and properties

Weight savings in the range from 25 to 35 percent could be achieved on Space Shuttle orbiter components and the thermal protection system (TPS) by employing a suitable graphite/polyimide (Gr/Pi) composite material system as a substitute for the baseline aluminum structural material. Predicted weight savings are based on the superior strength and stiffness-to-density ratios of Gr/Pi composite material over metallic counterparts. Specific strength and stiffness properties of Celion/Larc-160 composite laminates are compared with aluminum and titanium alloys. Aspects of materials and processes development are discussed, taking into account Celion/Larc-160 composite cure cycle and tooling evolution, complex shaped component process development, mechanical and physical properties testing and results, and structural element design fabrication, testing, and results. Attention is given to a demonstration of materials and processing technology, and a Celion/Larc-160 materials and processes summary is presented.