Investigating the impacts of processing variability on tool-part interaction for interply-toughened aerospace composites using a novel shear technique

Abstract

This study aims to investigate uncertainties in tool-part interaction during manufacturing of advanced aerospace composites. To achieve this goal, a custom-built shear test was developed using a Dynamic Mechanical Analyzer (DMA) to directly characterize tool-part interfacial stresses during composites processing. This novel method was used to quantify tool-part stresses during processing of interply-toughened Toray T800S/3900-2B on a steel tool with various conditions, accounting for variables such as the number of release coats on the tool, cure pressure and temperature, laminate layup, and strain rate. The observed trends in results were correlated with tool and part surface microstructures, investigated by laser scanning digital microscopy. This study’s findings underscored that the number of release coats, cure pressure, and temperature significantly influence tool-part interaction due to altered surface conditions and viscoelastic behaviors at the tool-part interface.