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In situ processing methods for composite fuselage sandwich structuresConventional sandwich structure fabrication methods are labor intensive and high in cost. A low cost method is needed to produce lightweight sandwich structures. Sundstrand has developed a series of in situ composite fabrication methods in which the raw materials (skin and core materials) are placed in a closed mold, and the component is produced in one heating cycle. Internal pressure is generated by chemical agents during the thermal cycles, which consolidates the skins and produces the foam core. The finished part is a net-shape composite sandwich structure with skins and a foamed core. The in situ process reduces cost by eliminating several secondary operations that are used in conventional fabrication methods. Further, a strong molecular bond is produced between the core and skin, which eliminates adhesive bonding and prevents a weak bond section in the sandwich structure. In this investigation, we evaluated the feasibility of the in situ process using thermoset materials currently under consideration for commercial airplane fuselage applications, such as keel sections. The materials used were Hercules 855340 toughened epoxy resin in both liquid and powder forms, and 3M Scotchply PR500 resin, manufactured by 3M Corporation, in powder form. We successfully foamed these resins and produced experimental panels with AS-4/855340 Hercules prepreg skins. Chopped fibers were added to the core to increase performance of the foam. Mechanical property testing on these panels showed properties competitive with other foams. Additional experiments are required to optimize the in situ foam core sandwiches for specific properties and applications.
Document ID
19950022405
Acquisition Source
Legacy CDMS
Document Type
Conference Paper
Authors
Saatchi, Hossein
(Sundstrand Aviation-Rockford IL, United States)
Durako, Bill
(Sundstrand Aviation-Rockford IL, United States)
Reynolds, Dick
(Sundstrand Aviation-Rockford IL, United States)
Dost, Ernest
(Boeing Co. Seattle, WA., United States)
Willden, Kurtis
(Boeing Co. Seattle, WA., United States)
Date Acquired
August 16, 2013
Publication Date
January 1, 1993
Publication Information
Publication: NASA. Langley Research Center, Third NASA Advanced Composites Technology Conference, Volume 1, Part 2
Subject Category
Composite Materials
Accession Number
95N28826
Distribution Limits
Public
Copyright
Work of the US Gov. Public Use Permitted.
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