CompositesWorld
Issue link: https://cw.epubxp.com/i/532917
CompositesWorld.com 19 NEWS N E W S N S N E W S E N W S W WORK IN PROGRESS By Ginger Gardiner / Senior Editor A new polymer and a hybrid process enable production of complex, high-load-capable, fiber-reinforced brackets and clips in minutes. ยป In the composites industry, use of polyetheretherketone (PEEK) has recently experienced an uptick in thermostamped aircraft fuselage clips and brackets made from preconsolidated blanks with woven and/or unidirectional reinforcements (see "Learn More," p. 20). But those who use and those who make the blanks recognize their limitations. "About 3-4 years ago, we recognized that compression-formed laminates did not ofer the design fexibility and manufacturing efciency being sought by aircraft designers," says Tim Herr, aero- space strategic business director for PEEK supplier Victrex Polymer Solutions (Cleveleys, Lancashire, UK). Drawing on the high- temperature-capable, high-performance resins' 25-year history in the aircraft industry in both flled and unflled injection molded plastic parts, such as mounts and spacers, tubing, housings and electrical connectors, Herr's Victrex team and aerospace parts manufacturer Tri-Mack (Bristol, RI, US) began to explore the concept of injection overmolding as a means of overcoming the limitations inherent in thermostamping of preconsolidated blanks. "Te industry needed overmolding," he explains, like the organosheet process now common with polyamides and polypro- pylene in the automotive industry (see "Learn More"). Aerospace parts manufacturer Tri-Mack (Bristol, RI, US) already had begun exploring this type of PEEK processing as part of its thermoplastic composites development. Te two have now demonstrated a new hybrid molding process for PEEK that uses a lower tempera- ture continuously-reinforced Victrex polyaryletherketone (PAEK) composite as a substrate, overmolded with short fber-reinforced PEEK, to produce a high-performance loaded bracket that is as much as 60% lighter than comparable metal components. Hybrid composites-plastic processing "Our idea was to combine the chemical resistance and moldability of thermoplastics with the high performance and light weight of composites," says Tri-Mack director of sales Tom Kneath. "Only then can thermoplastic composites penetrate into new applica- tions where plastic alone cannot go because of the mechanical properties required." But the organosheet process is not without issues. Traditional steps include preheating a preconsolidated thermoplastic laminate to remelt temperature, transfer to an Overmolding expands PEEK's range in composites Hybrid overmolding design This CAD image shows a continuous-fber-rein- forced PAEK composite (red) with a PEEK overmold (green). Source | Tri-Mack