Carbon fiber evaluation for directed fiber preforms

A key factor in manufacturing cost-effective composite structures is fabricating quality fiber performs for subsequent low cost resin infusion. A technology called the Programmable Powdered Preform Process (P4) has been developed to fabricate discontinuous fiber preforms for automotive applications. The U.S. Air Force has funded an effort to extend this technology to carbon fiber performs for aerospace applications (P4A). As the technology has been adapted for applying carbon fibers, the fiber form has become an important parameter of the preform process. Many carbon 'fiber form' parameters have been evaluated for their effects on oriented, discontinuous perform manufacturing. The parameters include tow size, tow shape, twist, sizing, packaging form, properties, and cost. Manufacturing trials with different fiber forms were conducted. A validated cost model was used to assess the effect of fiber cost and tow size on preform cost This evaluation is assisting in the development of a fiber form that is most compatible with the P4/P4A manufacturing technology, thus providing for a high quality preform that will result in significantly reduced component costs.