Automated Fiber Placement Manufactured Composites for Science Applications

Science instruments with large collecting areas that maintain dimensional stability, such as James Webb Space Telescope and Wide Field Space Telescope, help achieve next generation science advancements. Composite materials often used for science applications include high modulus fibers in cyanate ester matrices to result in dimensionally stable structures with low contamination. Hand lay-up fabrication is the most common approach for science instrument structures. Automated Fiber Placement (AFP) using intermediate modulus fibers is commonplace in aircraft production reducing manufacturing time and increasing quality and consistency. AFP manufacturing for future large science instruments can similarly reduce costs and increase reliability. However, high modulus fibers are more prone to damage than intermediate modulus fibers. This study investigates the manufacturing viability of M55J/RS3C (Tencate) slit tape material using AFP processing. Tencate provides slit tape materials. NASA Langley Research Center (LaRC) manufactured hand layup and AFP lay-up laminates under room temperature for initial trials, Marshall Space Flight Center (MSFC) manufactured AFP laminates under room temperature and elevated temperature conditions to evaluate processing affects. Goddard Space Flight Center (GSFC) tests and evaluates tension and Coefficient of Thermal Expansion (CTE) properties by hand lay-up and AFP slit tape automated manufacturing for large science applications. These results show processing material warm reduces process induced fiber fracture; leading to stiffness and CTE properties consistent with hand lay-up, while observing a slight degradation in tensile strength.