Method of Manufacturing Sheet.pdf

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METHOD OF MANUFACTURE

FOR:

Composite Batten Spring: Moulding

CUSTOMER: FRL

DOCUMENT NUMBER: 2380-1337_MOM001

DOCUMENT ISSUE: Issue 1

DATE: 28/09/09

MODIFICATION RECORD

ISSUE DATE REASON

INTERNAL

APPROVAL

EXTERNAL

APPROVAL

1 28/09/09 Initial Issue

THIS METHOD OF MANUFACTURE IS NOT TO BE USED OR CHANGED WITHOUT AUTHORISATION

DRAWING NUMBERS : 65081337

Batten Spring ISSUE: A

TOOLING, JIGS & FIXTURES: Press Tool Upper Platen C2380-02 UPPER

Press Tool Lower Platen C2380-02 LOWER

Spacer Plate C2380-01 (2.88MM THICK)

MATERIALS :

S2 Glass UD Pre-Preg

MTM46/449-AA-250-280-28% PREF00M4644925028

S2 Glass Woven

MTM46/6580-28% PREF00M466580028

T700 Carbon UD

MTM46/T700SC(24K)-295-32% PREF00M4670029532

Bagging Film Elastomax 260 SHTM00M260/A

Breather Blanket Airbleed 10 SHTM00M010

Peel Ply BR-100 SHTM00M100

Release Film A5000 SHTM00M005000

Sealant Tape GS213 TPEG00M00213

CUSTOMER

SPECIFICATIONS :

DS 01.14 (“Part Marking”)

COBHAM SPECIFICATIONS : CCPS 101 – Release Agents CCPS 102 – Pre-Preg

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Operator ID:

Date:

STAGE TITLE STAGE ISSUE

Document Check 0 1

Caul Plate Preparation 1 1

Press Tool Preparation 2 1

Material Preparation 3 1

Lay-Up 4 1

Moulding and Post Cure 5 1

Trimming 6 1

Stage Inspection 7 1

0. DOCUMENT CHECK

0.1 Ensure the Job Number and Document Issue given at the top of each page of this document coincides with the first table on page one.

0.2 For verifications use operator stamp. A signature is required if a stamp is not available.

1. CAUL PLATE PREPARATION

1.1 Obtain a caul plate ~600mm x ~500mm. These should be reasonably clean and flat to enable this composite panel to be moulded (note no specific tool has be allocated for this part). If there is any doubt about the suitability of the plates refer to Engineering.

1.2 Ensure the mould plate moulding surfaces are undamaged and clean.

1.3 Operator Verification Required

Confirm plates have no damage or contamination on the moulding faces. If tooling is found to be unacceptable, refer to your supervisor.

1.4 When using the plates for first time (or if a long period has elapsed between uses) wipe tool(s) with acetone. When clean, give the moulding surfaces three coats of Frekote B-15 mould sealant, allowing between 30 minutes to 1 hour between coats. After the third coat allow up to 24 hours at room temperature (or alternatively the cure process can be shortened by baking the mould for 60 minutes (+15 minutes/- 0 minutes) at 100°C ± 5°C after ensuring that the mould is dry and all solvents have flashed off).

1.5 Before each use, apply release agent to the tool (Frekote 700NC), applying three coats, allowing up to 15 minutes after each application for temperatures between 16 and 35 o C. The final coat should be dried for 20 minutes for temperatures between 16 and 35 o C. The film should be dry and not feel tacky prior to moulding. The release agent should be applied evenly and lightly using clean cotton cloths. Apply the release in a direction perpendicular to the previous direction

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1.6 Operator Verification Required

The operator must verify all Preparation operations have been carried out correctly.

2. PRESS TOOL PREPARATION

2.1 Obtain PRESS TOOLS c2380-02 Upper & Lower tool & 3.025mm Spacer Plate C2380-01.

2.2 Ensure the moulding surfaces are undamaged and clean.

2.3 Operator Verification Required

Confirm plates have no damage or contamination on the moulding faces. If tooling is found to be unacceptable, refer to your supervisor.

2.4 When using the plates for first time (or if a long period has elapsed between uses) wipe tool(s) with acetone. When clean, give the moulding surfaces three coats of Frekote B-15 mould sealant, allowing between 30 minutes to 1 hour between coats. After the third coat allow up to 24 hours at room temperature (or alternatively the cure process can be shortened by baking the mould for 60 minutes (+15 minutes/- 0 minutes) at 100°C ± 5°C after ensuring that the mould is dry and all solvents have flashed off).

2.5 Before each use, apply release agent to the tool (Frekote 700NC), applying three coats, allowing up to 15 minutes after each application for temperatures between 16 and 35 o C. The final coat should be dried for 20 minutes for temperatures between 16 and 35 o C. The film should be dry and not feel tacky prior to moulding. The release agent should be applied evenly and lightly using clean cotton cloths. Apply the release in a direction perpendicular to the previous direction

2.6 Operator Verification Required

The operator must verify all Preparation operations have been carried out correctly.

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3. MATERIAL PREPARATION

3.1 Obtain pre-preg material as shown in Table 1 below.

Table 1

Material Designation Stock Code Quantity

S2 Glass UD Pre-Preg MTM46/449-AA-250-280-28% PREF00M4644925028 0.6 m²

S2 Glass Woven Pre-Preg MTM46/6580-28% PREF00M466580028 1 m²

T700 Carbon UD Pre-Preg MTM46/T700SC(24K)-295-32% PREF00M4670029532 0.6 m²

3.2 Operator Verification Required

Ensure all materials have fully acclimatised to room temperature before removal from sealed packaging and use. Ensure all materials have not exceeded their shelf lives.

For the MTM46 material the shelf life is 12 months at -18°C, or 60 days at 21°C (room temperature).

Operator to Record material batch number (GRN) on route card and ensure that the Material Control Card (M.C.C.) is correctly filled in. Operator to ensure all kits stored away from the M.C.C. have the Shelf Life details included with them. If kits are to be used immediately for moulding refer to lay-up section.

S2 Glass UD Pre-Preg MTM46/449-AA-250-280-28% PREF00M4644925028 (12 months at -18°C, or 60 days at 21°C)

No. of

Mouldings:

Within Shelf

Life:

Fully acclimatised:

GRN

Number:

Panels:

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S2 Glass Woven Pre-Preg MTM46/6580-28% PREF00M466580028 (12 months at -18°C, or 60 days at 21°C)

T700 Carbon UD Pre-Preg MTM46/T700SC(24K)-295-32% PREF00M4670029532 (12 months at -18°C, or 60 days at 21°C)

3.3 Operator Verification Required

The operator must verify all Material Preparation operations have been carried out correctly.

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4. LAY-UP

4.1 Cut the plies of material required as per Table 2 below.

Table 2

Material Ply Sizes Orientation Tolerance

Quantity

S2 Glass UD Pre-Preg 410mm x 410mm ± 1° 4 off

S2 Glass Woven Pre- Preg

410mm x 410mm ± 1° 8 off

T700 Carbon UD Pre- Preg

410mm x 410mm ± 1° 4 off

4.2 Ensure the tool has been prepared as per Stage 1.

4.3 Lay up the panel in the centre of the peel ply, in the order shown in Table 3 below. Note all plies must be laid up within ± 1° of the nominal 0° direction and all UD plies must be laid up within ± 0.5° of the nominal 0° direction.

Table 3

Ply Number Material Notes Orientation Operator Check

1 PREF00M4644925028 (U/D Glass) Do not remove the pre-preg backing which on the tool side 0°

2 PREF00M4644925028 (U/D Glass) - 0°

3 PREF00M466580028 (S2/Woven) - 0°

4 PREF00M4670029532 (U/D Carbon) - 0°

De-Bulk IAW 3.4

5 PREF00M4670029532 (U/D Carbon) - 0°

6 PREF00M466580028 (S2/Woven) - 0°

7 PREF00M466580028 (S2/Woven) - 0°

8 PREF00M466580028 (S2/Woven) - 0°

De-Bulk IAW 3.4

9 PREF00M466580028 (S2/Woven) Reverse (“flip”) plies 0°

10 PREF00M466580028 (S2/Woven) Reverse (“flip”) plies 0°

11 PREF00M466580028 (S2/Woven) Reverse (“flip”) plies 0°

12 PREF00M4670029532 (U/D Carbon) Reverse (“flip”) plies 0°

De-Bulk IAW 3.4

13 PREF00M4670029532 (U/D Carbon) Reverse (“flip”) plies 0°

14 PREF00M466580028 (S2/Woven) Reverse (“flip”) plies 0°

15 PREF00M4644925028 (U/D Glass) Reverse (“flip”) plies 0°

16 PREF00M4644925028 (U/D Glass) Reverse (“flip”) plies 0°

De-Bulk IAW 3.4

4.4 When de-bulking cover lay-up in perforated release film and breather blanket, and seal in a vacuum bag. Apply “full” vacuum (24-27 ins Hg) at room temperature for a minimum of 15 minutes.

4.5 When the lay up is complete cover the lay up cover the exposed preform face with a layer of new peel ply.

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4.6 If the perform is not to be immediately press moulded, store in a sealed polythene bag with the freezer card. Return to freezer storage if the remaining Room Temperature life is not enough for the expected moulding date.

4.7 Operator Verification Required

The operator must verify all Lay Up operations have been carried out correctly.

MOULDING

5.1 Check the mould temperature has achieved 125C 5C.

5.2 Ensure tool has been Released. To mould release between mouldings, apply Frekote 700NC with a clean lint free cloth. Ensure that the release has fully flashed off prior to moulding

5.3 Operator Verification Required

Check the preform Freezer cards (for Shelf life and Expiry date) prior to moulding to ensure material is still within life.

5.4 Transfer the stack to the mould tool (C2380-02) that has been pre-heated in the to 125C 5C. Place lay up inside frame and close the press within one minute. Close the platens to achieve a minimum pressure of 3.5MPa tom 6.9MPa ( Press PSS04 tonnage should achieve 137KN to 269KN ). Consult Engineering if another press is to be used.

5.5 Whilst maintaining pressure ramp the temperature to 125°C ± 5°C and cure for 60 to 75 minutes (set timer to 60 minutes).

5.6 Hot demould and transfer to a holding oven set to 125°C ± 5°C.

5.7 Apply tempory part mark (Job Number, Route card Number and panel number eg 1,2,3 within the router card batch for cure traceability)

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5.8 Operator Verification Required

Upon completion of the Press cure, ensure the press cycle has been completed in accordance with the above and attach cure chart to route card. Report any deviations to supervision.

Ensure the shelf life of the pre-preg has not been exceeded at the time of cure.

5.9 At the end of the shift heat the moulding panels (current held at 125 o C) at 0.3 o C/minute to 180±5 o C and hold for 60 to 90 minutes. Cool at a rate of 3 o C/min maximum to 60

C.

5.10 Operator Verification Required

Upon completion of the cure, ensure the cure cycle has been completed in accordance with the above and attach cure chart to route card. Report any deviations to supervision.

Cure Date:

Oven ID:

Channel:

Start Time:

Finish time:

Press

Cure Date:

Oven ID:

Channel:

Start Time:

Finish time:

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Inspector

ID:

6. TRIMMING

6.1 Trim off mould flash and remove any sharp edges. Ensure that the datum edges are maintained.

Note cut resistant gloves should be worn during this process. Mark the 0 direction on the panel

6.2 Operator Verification Required

The operator must verify all Trimming operations have been carried out correctly.

7.0 STAGE INSPECTION

7.1 Check the quality of both upper and lower moulded surfaces. Faces are to be smooth and resin sealed. Also check the panel for flatness. Consult engineering if such defects are identified.

7.2 Check that the Fibre runs across the width (410mm) direction on both sides.

7.3 Check the trimmed edge for no visible deformation, voids or delamination.

7.4 Check the thickness of the plate is within the tolerance shown on drawings (3.025mm±0.075mm).

7.5 Check the components cure cycle records.

7.6 Inspector Verification Required

Inspection must verify all operations have been carried out correctly.