Design, manufacturing and testing of a rotorcraft access panel door from recycled carbon fiber reinforced polyphenylenesulfide

Thomas de Bruijn, Guillaume Almire Vincent, Johan Meuzelaar, J.P. Nunes, Ferrie van Hattum

Research output: Contribution to conferencePaperAcademicpeer-review

Abstract

An integrally-stiffened access panel for a rotorcraft is selected for detail design, testing and actual flight to demonstrate a novel recycling route for thermoplastic composites. The design, development and validation followed the ‘Building Block approach’. The used material is post-industrial carbon fiber reinforced polyphenylene sulfide waste. This material originates from thermoplastic components of the very same rotorcraft as the panel will be mounted on, improving traceability, logistics and fixing supply and demand. Material data have been gathered from mechanical tests and used to predict the panels strength and stiffness. A critical design detail was selected and tested for validation. This section was included in a manufacturing demo, along with other integrated design features, enabling testing the processability. The final panel design was successfully produced and tested on component level. The re-manufacturing process includes simultaneously applied heat and low-shear mixing, followed by compression molding in an isothermal mold. This offers the possibility to retain long fibers and therefore high mechanical properties at short cycle times. In comparison to the current carbon/epoxy solution, the resulting product is lighter, significantly more cost-effective and made of recycled material (fiber and matrix). The prototype panel is targeted for flight testing on the rotorcraft in 2019.
Original languageEnglish
DOIs
Publication statusPublished - 23 May 2019
EventSAMPE North America Conference and Exhibition 2019 - Charlotte Convention Center, Charlotte, United States
Duration: 20 May 201923 May 2019

Conference

ConferenceSAMPE North America Conference and Exhibition 2019
CountryUnited States
CityCharlotte
Period20/05/1923/05/19

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Carbon fibers
Testing
Thermoplastics
Compression molding
Fibers
Logistics
Recycling
Stiffness
Mechanical properties
Carbon
Composite materials
Costs

Cite this

de Bruijn, T., Vincent, G. A., Meuzelaar, J., Nunes, J. P., & van Hattum, F. (2019). Design, manufacturing and testing of a rotorcraft access panel door from recycled carbon fiber reinforced polyphenylenesulfide. Paper presented at SAMPE North America Conference and Exhibition 2019, Charlotte, United States. https://doi.org/10.33599/nasampe/s.19.1437
de Bruijn, Thomas ; Vincent, Guillaume Almire ; Meuzelaar, Johan ; Nunes, J.P. ; van Hattum, Ferrie. / Design, manufacturing and testing of a rotorcraft access panel door from recycled carbon fiber reinforced polyphenylenesulfide. Paper presented at SAMPE North America Conference and Exhibition 2019, Charlotte, United States.
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de Bruijn, T, Vincent, GA, Meuzelaar, J, Nunes, JP & van Hattum, F 2019, 'Design, manufacturing and testing of a rotorcraft access panel door from recycled carbon fiber reinforced polyphenylenesulfide' Paper presented at SAMPE North America Conference and Exhibition 2019, Charlotte, United States, 20/05/19 - 23/05/19, . https://doi.org/10.33599/nasampe/s.19.1437

Design, manufacturing and testing of a rotorcraft access panel door from recycled carbon fiber reinforced polyphenylenesulfide. / de Bruijn, Thomas; Vincent, Guillaume Almire; Meuzelaar, Johan; Nunes, J.P.; van Hattum, Ferrie.

2019. Paper presented at SAMPE North America Conference and Exhibition 2019, Charlotte, United States.

Research output: Contribution to conferencePaperAcademicpeer-review

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AU - de Bruijn, Thomas

AU - Vincent, Guillaume Almire

AU - Meuzelaar, Johan

AU - Nunes, J.P.

AU - van Hattum, Ferrie

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AB - An integrally-stiffened access panel for a rotorcraft is selected for detail design, testing and actual flight to demonstrate a novel recycling route for thermoplastic composites. The design, development and validation followed the ‘Building Block approach’. The used material is post-industrial carbon fiber reinforced polyphenylene sulfide waste. This material originates from thermoplastic components of the very same rotorcraft as the panel will be mounted on, improving traceability, logistics and fixing supply and demand. Material data have been gathered from mechanical tests and used to predict the panels strength and stiffness. A critical design detail was selected and tested for validation. This section was included in a manufacturing demo, along with other integrated design features, enabling testing the processability. The final panel design was successfully produced and tested on component level. The re-manufacturing process includes simultaneously applied heat and low-shear mixing, followed by compression molding in an isothermal mold. This offers the possibility to retain long fibers and therefore high mechanical properties at short cycle times. In comparison to the current carbon/epoxy solution, the resulting product is lighter, significantly more cost-effective and made of recycled material (fiber and matrix). The prototype panel is targeted for flight testing on the rotorcraft in 2019.

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de Bruijn T, Vincent GA, Meuzelaar J, Nunes JP, van Hattum F. Design, manufacturing and testing of a rotorcraft access panel door from recycled carbon fiber reinforced polyphenylenesulfide. 2019. Paper presented at SAMPE North America Conference and Exhibition 2019, Charlotte, United States. https://doi.org/10.33599/nasampe/s.19.1437