The design, fabrication and characterization of an advanced graphite composite structure for high speed rotating machines

Mobile rotating machines require lightweight, high strength and energy absorptive containment structures. This paper reports the results of a program to develop the manufacturing processes and demonstrate the feasibility of fabricating a representative complex shape carbon fiber-epoxy composite endplate. The part geometry and composite architecture were designed to meet or exceed the structural performance of a current titanium alloy endplate design. An integrally heated 16-piece aluminum mold was designed and fabricated. The mold cavity was filled with carbon fiber preforms designed to produce the fiber orientation and volume fraction necessary to meet the directional structural property requirements. A near net-shape carbon fiber-epoxy part was successfully produced utilizing the resin transfer molding (RTM) process. The mechanical properties and quality of the resulting part were characterized and are reported. The composite endplate would result in significant weight savings over the titanium part it replaced.