Performance of a Filament Wound Graphite/Thermoplastic Composite Ring-Stiffened Pressure Hull Model

Abstract

The design, analysis, manufacture, and hydrostatic testing results of a 24- inchdiameter ringstiffened pressurehull model are presented. The AS-4 graphite/PEEK cylinder is manufactured using a nonautoclave insitu filament winding and tape laydown process. The cylinder incorporates 5 hoopwound rings and a shell (hoop/axial construction) that are integrally wound during manufacture. Ultrasonic inspection in conjunction with optical microscopy of end rings indicates that high quality is achieved with a void content of less than 1%. Translation of coupon data into the structure is quantified by subcomponent tests that measure insitu properties (A and Bbasis allowables) including shell axial compressive stiffness and strength and interlaminar shear strength. Analysis of the structure indicates that high interlaminar shear stress exists in the ring fillet areas. Subcomponent tests with supporting analysis to design the test method indicated that this failure mode was not critical. Design and analysis efforts focused on midbay and endbay performance. Axial compressive stress concentrations in the endbay were reduced by incorporating local increases in shell thickness and a steel insert ring that provided radial constraint of the shell to reduce the probability of an endbrooming failure mode. Steel hemispherical heads were designed and manufactured to further reduce axial compressive stress concentrations in the endbay. The test model was instrumented with strain gages and acoustic emission sensors and tested at Carderock Division, Naval Surface Warfare Center (CD-NSWC). Increments in pressure were followed by a 5-minute dwell time. Acoustic emission ceased for all pressures except the last two increments at 5250 and 5500 psi. The collapse pressure of 5500 psi was within 3% of our Bbasis prediction. The cylinder weight-to-displacement ratio, W/D, was 0.212 (unitless). Axial compression failure occurred in the cylinder midbay in agreement with our analysis.

A comparison of mechanical properties and X-ray tomography analysis of different out-of-autoclave manufactured thermoplastic composites

“…Better quality raw thermoplastic tapes, especially with constant ply thickness, fewer intralaminar voids and good fibre/matrix distribution, would be also beneficial for optimal lamination and final quality of the laminates, as also concluded by other investigations. 33,34,54,57 The use of re-passes may also be of assistance for a better final laminate quality. Thus, further research focused on the investigation of different material grade and different lamination strategies for the improvement of the quality of ISC laminates is proposed.…”

“…Those studies indicated the need of higher quality raw prepreg tapes for decreasing the final void content, therefore increasing the mechanical properties closer to autoclaved levels. 33,34 Higher quality thermoplastic tapes may consist of low intralaminar void content, good fibre and matrix distribution and parallel surfaces. In the meanwhile, low deposition speed, high compaction forces, good lay-up strategies, self-heated tools and a proper temperature control are generally proposed to address good quality thermoplastic parts.…”

Design, Analysis, Manufacture, and Test of APC-2/AS4 Thermoplastic Composite Pressure Vessels for Deep Water Marine Applications

“…However, most of the previous studies developed composite pressure vessels with thin to intermediate wall thickness and radiusto-thickness ratios of greater than ten, for example see [2,3,5,6]. Several thick-wall pressure vessels were designed, manufactured, and tested and found to fail prematurely [7] due to the lack of understanding of thick-section composite structures' mechanical behavior, effects of the end-caps, and/or manufacturing issues.…”

Thermoplastic Composite Cylinders for Underwater Applications

“…That study concentrated on tape placement and several carbon reinforced thermoplastics were examined including PPS, PEI, PEEK, and PEKK, and a number of cylinders were tested [4][5][6]. Further details of the thermoplastic composite tape placement technique were presented recently [7].…”