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Carbon Tape Material Specification

This document outlines the specifications for carbon tape materials used in engineering applications. It addresses essential topics including the approval process for Product Change Documentation (PCD), equivalency demonstrations for prepreg production, and standardized exposure conditions for moisture conditioning. Additionally, it details quality criteria, testing protocols, and supplier responsibilities. Recommendations for identifying sources of variability in composite materials and future needs are also discussed, along with comprehensive guidelines for composite fabrication and bonding techniques.

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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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