SAE AMS 3961-2015 350 Autoclave Cure Low Flow Toughened Epoxy Prepregs.pdf

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1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref

2、rom, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2015 SAE InternationalAll rights reserved. No part of this publi

3、cation may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE.TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada)Tel: +1 724-776-4970 (out

4、side USA)Fax: 724-776-0790Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visithttp:/www.sae.org/technical/standards/AMS3961AEROSPACEMATERIAL SPECIFICATIONAMS3961Issued 2015-12350 F Autoclave Cure, Low Flow Tou

5、ghened Epoxy PrepregsRATIONALEWidely distributed and available industry material specifications are required for procurement of composite materials whose allowables data is published in CMH-17.TABLE OF CONTENTS1. SCOPE. 3 1.1 Form. 3 1.1.1 Detail Specification. 3 1.2 Purpose 3 1.3 Classification 3 1

6、.3.1 Type . 3 1.3.2 Class 3 1.3.3 Grade . 3 1.3.4 Style . 4 1.3.5 Fiber Type 4 1.3.6 Service Temperature Capability. 4 1.4 Safety Hazardous Materials 4 1.5 Change Control Management 42. APPLICABLE DOCUMENTS. 4 2.1 SAE Publications 4 2.2 ASTM Publications. 5 2.3 ISO Publications. 5 2.4 SACMA Standard

7、s . 5 2.5 U.S. Government Publications. 6 2.6 Definitions 63. TECHNICAL REQUIREMENTS. 8 3.1 Composition . 8 3.1.1 Resin 8 3.1.2 Reinforcement 8 3.2 Quality 9 3.2.1 Visual Defect Limitations and Dimensional Requirements (Class 1). 9 3.2.2 Visual Defect Limitations and Dimensional Requirements (Class

8、2). 10 3.2.3 Materials Not Conforming to the Visible Defect Limitations and Dimensional Requirements . 10 3.2.4 Storage and Handling Requirements. 10 3.2.5 Prepreg Life Requirements 11 3.2.6 Distributors . 12 3.2.7 Environmental, Health, and Safety 12 3.2.8 Uncured Prepreg Physical and Chemical Prop

9、erties. 12 3.3 Composite (Cured Prepreg) Requirements . 13 SAE INTERNATIONAL AMS3961 Page 2 of 283.3.1 Cured Laminate Physical Properties13 3.3.2 Cured Laminate Mechanical Properties. 14 3.4 Traceability. 15 3.5 Manufacturers Responsibility 15 3.6 Quality Management System. 154. QUALITY ASSURANCE PR

10、OVISIONS. 15 4.1 Initial Material Qualification 15 4.1.1 Request for Initial Material Qualification 16 4.2 Equivalency Programs . 16 4.2.1 Material Equivalency 16 4.2.2 Processor Equivalency. 17 4.2.3 Request for Equivalency Determination. 17 4.3 Production Quality Assurance 17 4.3.1 Responsibility

11、for Inspection 18 4.3.2 Classification of Tests and Inspections 18 4.3.3 Statistical Process Control . 18 4.3.4 Product Certification. 19 4.3.5 Purchaser Quality Control 20 4.4 Material Test Methods 21 4.4.1 Tack (Prepreg) . 22 4.4.2 Drape (Prepreg) . 23 4.4.3 Retest. 23 4.5 Test Panel Fabrication .

12、 235. PREPARATION FOR DELIVERY 25 5.1 Labeling 25 5.2 Packaging, Marking and Shipping .26 5.2.1 Carrier Material 26 5.2.2 Roll Size . 26 5.2.3 Core Configuration. 26 5.2.4 Packaging 26 5.2.5 Marking. 27 5.2.6 Shipping . 27 5.2.7 Receipt at Purchaser 276. ACKNOWLEDGMENTS.287. REJECTIONS 288. NOTES. 2

13、8 8.1 Revision Indicator. 28 Figure 1 Definitions of storage, handling, and staging life and out-time 8Figure 2 Specimen traceability lines 22Figure 3 Vacuum bag assembly. 24Figure 4 Cure cycle 25Table 1 Acceptance/Rejection criteria for puckers and/or pimples. 9Table 2 Uncured prepreg physical and

14、chemical properties. 13Table 3 Cured laminate physical properties 13Table 4 Required cured laminate level tests for mechanical properties (class 1 only) 14Table 5 Required cured laminate level tests for mechanical properties (class 2 only). 14Table 6 Supplier quality control sampling plan for lamina

15、te mechanical properties . 15SAE INTERNATIONAL AMS3961 Page 3 of 281. SCOPEThe intent of this specification is for the procurement of the material listed on the QPL and, therefore, no qualification orequivalency threshold values are provided. Users that intend to conduct a new material qualification

16、 or equivalency program shall refer to the Quality Assurance section of this base specification, AMS3961.All material qualification and equivalency data has been archived and is available for review upon request. Contact the CMH-17 Secretariat (www.cmh17.org) for additional information.1.1 FormThis

17、specification and its associated detail specifications establish the requirements for a 350 F autoclave cure, continuous fiber (“unidirectional tape and fabric prepreg”) impregnated with a modified B-staged epoxy resin. 1.1.1 Detail SpecificationThis base specification contains basic fiber reinforce

18、d epoxy prepreg material requirements that apply to every product. The detail specifications contain additional or superseding properties and requirements that apply to a specific product.1.2 Purposea. The purpose of this specification is to allow procurement of a defined material corresponding to t

19、he statistically derived material properties published in CMH-17.b. The materials qualified to this specification are designed specifically for vacuum-bag autoclave cure in accordance with 4.5. c. This specification is developed based on the material properties that are available publicly. The purch

20、aser may specify additional requirements beyond those defined in this specification, especially when the purchaser has generated additional material properties beyond those available publicly or when the application has other requirements. The additional requirements are subject to supplier review a

21、nd approval.d. The use of this specification does not guarantee material or structural performance. Material users should be actively involved in evaluating material performance and quality including, but not limited to, performing regular purchaser quality control tests, performing periodic equival

22、ency/additional testing, participating in material change management activities, conducting statistical process control, and conducting regular supplier audits.e. This material is intended for use in laminate applications with a service temperature range of -65 to 250 F.f. This composite material ma

23、y be used for the manufacture of primary and secondary aircraft structure.1.3 Classification1.3.1 TypeType shall specify the nominal prepreg resin content. For example:Type 35 Nominal resin content 35% by weightType 38 Nominal resin content 38% by weight1.3.2 ClassClass shall specify prepreg product

24、 form. For example: Class 1 Unidirectional carbon fiber prepreg tapeClass 2 Woven carbon fiber fabric prepreg1.3.3 GradeGrade shall specify nominal fiber areal weight in grams per square meter (gsm). For example:Grade 190 190 gsm nominal fiber areal weightGrade 193 193 gsm nominal fiber areal weight

25、SAE INTERNATIONAL AMS3961 Page 4 of 281.3.4 Style Style shall specify the woven fabric style (not applicable to Class 1). For example:Style 3K-70-PW - 3k yarn, 7.0 mil nominal dry fabric thickness, plain weave1.3.5 Fiber TypeThe carbon fiber type is designated as follows:Fiber 1: Standard Modulus (3

26、1-35 Msi)Fiber 2: Intermediate Modulus (38-42 Msi)1.3.6 Service Temperature CapabilityThe service temperature capability, used to establish the batch acceptance test temperature requirements, shall be designated at follows:ST (Standard Temperature) - service temperature of -65 to 180 F All batch acc

27、eptance testing shall be performed at room temperature dry (70 F 10 F)ET (Elevated Temperature) service temperature of -65 to 250 F A portion of the batch acceptance tests shall be performed at elevated temperature dry (250 F 10 F).Note: If no service temperature capability is identified in the prod

28、uct nomenclature, then “ST” shall be the default designation1.4 Safety Hazardous MaterialsWhile the materials, methods, applications, and processes described or referenced in this specification may involve the use of hazardous materials, this specification does not address all the hazards which may

29、be involved in such use. It is the sole responsibility of the user to ensure familiarity with the safe and proper use of any hazardous materials and to take necessary precautionary measures to ensure the health and safety of all personnel involved.1.5 Change Control ManagementPrepreg product shall b

30、e produced in accordance with a Process Control Document (PCD) approved by the Qualifying Agency. In general, level 1 through level 3 changes per DOT/FAA/AR-06/10 and DOT/FAA/AR-07/3 are considered major changes. Prior to implementing a change, the material supplier shall provide formal notification

31、 to the Qualifying Agency. The change may not be implemented until approval has been provided by the Qualifying Agency.2. APPLICABLE DOCUMENTSThe issue of the following documents in effect on the date of the purchase order forms a part of this specification to the extent specified herein. The suppli

32、er may work to a subsequent revision of a document unless a specific document issue is specified. When the referenced document has been cancelled and no superseding document has been specified, the last published issue of that document shall apply.2.1 SAE PublicationsAvailable from SAE International

33、, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org.Detail SpecificationsAMS3961/1 350 F Autoclave Cure, Low Flow Toughened Epoxy Prepregs, Type 38, Class 2, Grade 193, Style 3K-70-PW, Fiber 1AMS3961/2 350 F Aut

34、oclave Cure, Low Flow Toughened Epoxy Prepregs, Type 35, Class1, Grade 190, Fiber 2AMS3961/3 350 F Autoclave Cure, Low Flow Toughened Epoxy Prepregs, Type 35, Class 1, Grade 190, Fiber 1(CMH-17) Composite Materials Handbook SAE INTERNATIONAL AMS3961 Page 5 of 282.2 ASTM PublicationsAvailable from AS

35、TM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.ASTM D2344 Short-Beam Strength of Polymer Matrix Composite Materials and their Laminates ASTM D3039 Tensile Properties of Polymeric Matrix Composite MaterialsASTM D3529/D3529M Ma

36、trix Solids Content and Matrix Content of Composite PrepregASTM D3530/D3530M Volatiles Content of Composite Material PrepregASTM D3531 Standard Test Method for Resin Flow of Carbon Fiber-EpoxyASTM D3532 Gel Time of Carbon Fiber-Epoxy PrepregASTM D3776 Mass per Unit Area (Weight) of FabricASTM D3878

37、Standard Terminology Composite MaterialsASTM D6641 Compressive Properties of Polymer Matrix Composite Laminates Using a Combined Loading Compression (CLC) Test FixtureASTM E168 General Techniques of Infrared Quantitative AnalysisASTM E1252 Standard Practice for Obtaining Infrared Spectra for Qualita

38、tive Analysis2.3 ISO PublicationsAvailable from American National Standards Institute, 25 West 43rd Street, 4th Floor, New York, NY 10036, Tel: 212-642-4900, www.ansi.org.ISO 9000 Quality Management Systems2.4 SACMA StandardsAvailable from American Composites Manufacturers Association, 1010 North Gl

39、ebe Road, Suite 450, Arlington, VA 22201, Tel: 703-525-0511, www.acmanet.org.SACMA SRM 10R-94 Calculation of Fiber Volume of Composite Test LaminatesSACMA SRM 18R-94 Glass Transition Temperature (Tg) Determination by DMA of Oriented Fiber Resin CompositesSACMA SRM 20R-94 High Performance Liquid Chro

40、matography of Thermoset ResinsSACMA SRM 23R-94 Resin Content and Fiber Area Weight of Thermoset Prepreg with Destructive TechniqueSACMA SRM 25R-94 Onset Temperature and Peak Temperature for Composite System Resins Using Differential Scanning Calorimetry (DSC)SAE INTERNATIONAL AMS3961 Page 6 of 282.5

41、 U.S. Government PublicationsCopies of these documents are available online at http:/quicksearch.dla.mil.29 CFR 1910.1200 Hazard Communication, Occupational Safety and Health StandardsDOT/FAA/AR-03/19 Material Qualification and Equivalency for Polymer Matrix Composite Material SystemsDOT/FAA/AR-06/1

42、0 Guidelines and Recommended Criteria for the Development of a Material Specification for Carbon Fiber/Epoxy Fabric PrepregsDOT/FAA/AR-07/3 Guidelines and Recommended Criteria for the Development of a Material Specification for Carbon Fiber/Epoxy Unidirectional Prepregs UpdateMILD3464 Desiccants, Ac

43、tivated, Bagged, Packaging Use and Static DehumidificationMIL-PRF-131 Barrier Materials, Watervaporproof, Greaseproof, Flexible, Heat-Sealable2.6 DefinitionsFor definitions that are not provided in this specification or other applicable AMS specifications, the definitions in DOT/FAA/AR-06/10 or DOT/

44、FAA/AR-07/3 shall apply. For definitions not provided in DOT/FAA/AR-06/10, the definitions in ASTM D3878 shall apply. For definitions not provided in ASTM D3878, the definitions in CMH-17 shall apply.ACCEPTANCE TESTING Tests to prove that the quality aspects of subsequent prepreg batches correspond

45、to the quality characteristics of the “original” qualified prepreg product.BAG SIDE The side of the panel that is cured against the vacuum bag.BREATHER A porous material that serves as a continuous air path over and/or around the part.CREASE A condition of the surface of the prepreg where the nomina

46、l thickness is not appreciably changed but the material is permanently formed into a ridge.FABRIC BATCH Fabric woven from one warp loom set.FIBER FINISH A coating material applied to the fiber in order to promote resin adhesion.FIBER (YARN) LOT Fiber produced in one continuous manufacturing operatio

47、n, under substantially identical conditions (except normal rest periods and daily shift changes).FIBER SIZING A coating or treatment applied to yarns to improve handling characteristics during weaving, prepregging or other fiber handling operations.FILL The crosswise yarns running at 90 degrees to t

48、he warp of the fabric reinforcements, also known as weft or 90.FOLD A condition in which the prepreg is laid back over itself.FOREIGN MATERIAL All visually detectable material not characteristic of the prepreg, such as not fiber or resin constituents.FUZZ BALLS The broken filaments and abraded parti

49、cles that collect as loose filament bundles or balls which are occasionally incorporated onto the impregnated material.MASTER ROLL A subunit of a prepreg batch that has been wound on a core, until changed with another empty core thatis further processed into product rolls.SAE INTERNATIONAL AMS3961 Page 7 of 28MECHANICAL LIFE See Figure 1 for Staging Life. The out-of