No-oven, no-autoclave processing for NASA composite structures

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No-oven, no-autoclave processing for NASA composite structures

Barnell, Thomas J. / Rauscher, Michael D. / Doudican, Bradley M. / Sutter, James K.

CRG (Cornerstone Research Group's) NONA (no-oven, no-autoclave) composite processing enables the fabrication of high-performance composite parts without the limitations imposed by autoclaves and ovens. We are actively expanding the NONA technology toolbox to enable fabrication of large, single-piece composite structures and to provide a low-cost manufacturing option for high-performance composite tooling. We have worked with NASA to significantly advance the TRL (technology readiness level) of NONA. Recognizing the challenges faced in the fabrication and use of composite tooling, we have examined NONA performance in maintaining vacuum integrity through cyclic thermal and mechanical loading, dimensional accuracy of both tool and finished parts, CTE (coefficient of thermal expansion) compatibility, quality surface finish, and infusion process compatibility. We have demonstrated these capabilities at various scales, including the fabrication of a NONA honeycomb sandwich structure with a 127 cm × 66 cm core and a 117 cm × 107 cm curved NONA composite tool for fabrication of test panels relevant to NASA's SLS (space launch system). We have nearly completed a comprehensive mechanical characterization of NONA carbon composites for comparison to benchmark aerospace material systems.