Aerospace Applications of Thermoplastic and Thermoset Composites

Sponsored by Toray Advanced CompositesOct 24 2013

Download the PDF selection guide for more information about Toray's aerospace composite solutions.

Toray has extensive experience in supplying out-of-autoclave/vacuum-bag-only epoxy prepregs. Toray has leading positions with OOA/VBO epoxy prepregs in general aviation fuselages and flight control surfaces. Toray’s precision film impregnation processes allow efficient and effective utilization of vacuum bag processing for improved part throughput and productivity.

Aerospace applications for advanced composites include:

General aviation and helicopters
Commercial and military aircraft
Space, satellite, and launch vehicles

Toray has leading positions on current and next-generation composite aircraft.

Materials Selection Guide – Aircraft

The materials selection guide for aircraft is shown in Table 1.

Table 1. Material selection guide for aircraft

Product Name	Resin Type	T_g	Cure Temp/ Cure Time	Description	Key Resin Characteristics
Prepregs
BT250E-1	Epoxy	257 °F/125 °C	60 minutes at 250 °F/121 °C	BT250E-1 is a good moderate service temperature prepreg Self adhesive to core Good toughness MIL-R-9300 qualified	30 days work life at 77 °F/25 °C Out of autoclave processible
BT250E-6 NEW	Epoxy	268 °F/131 °C	120 minutes at 260 °F/127 °C	High modulus resin system for rotor blade usage Out-of-autoclave processible FAA conformed database	30 days work life at 77 °F/25 °C
EX-1522	Epoxy	356 °F/180 °C	120 minutes at 350 °F/177 °C	Low moisture absorption, toughened Excellent mechanical properties	14 days tack life at 77 °F/25 °C
RS-8HT	BMI	545 °F/285 °C	120 minutes at 400 °F/204 °C, post cure of 360 minutes at 482 °F/250 °C	RS-8HT provides excellent elevated temperature properties with good toughness and moisture resistance Also available as an RTM resin	Fracture Toughness G1c 1.2 in - lb/in²
RS-51 AFRPE-4	Polyimide	734 °C/390 °C	Contact Toray for details.	Extremely high service temperature	10 days out life at 77 °F/25 °C
TC250	Epoxy	285 °F/140 °C or 356 °F/180 °C with post cure	60 minutes at 190 °F/88 °C, followed by 120 minutes at 265 °F/130 °C. Optional post cure of 60 minutes at 350 °F/177 °C for higher T_g	TC250 is a 250 °F/121 °C service prepreg. It is designed for vacuum bag cure or autoclave Good surfacing qualities Good toughness Self adhesive to core capability Postcurable	45 days tack life Hot/wet T_g 257 °F/125 °C
TC275-1 NEW	Epoxy	327 °F/164 °C or 362 °F/183 °C with 350 °F/177 °C post cure	360 minutes at 275 °F/135 °C Optional post cure of 120 minutes at 350 °F/177 °C	Designed for very low voids <0.5% in thick parts with out-of-autoclave vacuum cures May be cured at 275 °F/135 °C or 350 °F/177 °C	Very low moisture uptake High hot/wet T_g retention Longer tack life & outtime for larger parts
TC350-1 NEW	Epoxy	376 °F/191 °C	120 minutes at 350 °F/177 °C	TC350-1 is Toray's latest 350 °F/177 °C service out-of-autoclave prepreg. It is a toughened high temperature prepreg system Low moisture absorption Good hot/wet performance	21 days tack life, 45 days tool life Hot/wet T_g 320 °F/160 °C
TC420	Cyanate Ester	350 °F/177 °C or 658 °F/348 °C with post cure	3 hours at 350 °F/177 °C Optional post cure of 500 °F/260 °C for higher T_g	Toray's highest temperature cyanate ester Processes like an epoxy, yet yields a T_g and performance of a BMI Excellent thermal stability for use on heat shields and ablatives	14 days tack life 75 °F/24 °C
Thermoplastic Fabrics & Unitapes*
Toray Cetex^® TC925 FST NEW	Polycarbonate (PC)	307 °F/153 °C	Process temp - 437 °F/225 °C	Value oriented solution Good FST performance (OSU < 25/25) Translucent laminate with good chemical resistance Ideal for flooring, seating, and small parts	See data sheet for details.
Toray Cetex^® TC1000 Premium	Polyetherimide (PEI)	419 °F/215 °C	Process temp - 600 °F/315 °C	Qualified and certified to OEM specifications Excellent FST performance (OSU < 15/15) Industry leading mechanical performance Good solvent resistance Ideal for interior applications ranging from floor panels, to seat plynths to luggage bins	See data sheet for details.
Toray Cetex^® TC1000 Design	Polyetherimide (PEI)	419 °F/215 °C	Process temp - 600 °F/315 °C	RTL for customer design programs Excellent FST performance (OSU < 15/15) Range of colours and textures available Significant weight reduction in metal replacement programs	See data sheet for details.
Toray Cetex^® TC1100	Polyphenylene Sulfide (PPS)	194 °F/90 °C	Process temp - 625 °F/330 °C	Offered on either glass or carbon Moderate temperature capability and features: High impact resistance Low flammability Low moisture absorption of 0.02% Ideal for leading edges, structural aircraft parts including interior beams and floor panels	See data sheet for details.
Toray Cetex^® TC1200	Polyetheretherketone (PEEK)	290 °F/143 °C	Process temp - 725 °F/385 °C	Thermoplastic unitapes and fabrics Outstanding solvent resistance Low flammability	See data sheet for details.
Toray Cetex^® TC1220 NEW	Polyetheretherketone (PEEK)	290 °F/143 °C	Process temp - 725 °F/385 °C	50 ksi CAI thermoplastic PEEK unitapes	See data sheet for details.
Toray Cetex^® TC1320 NEW	Polyetherketoneketone (PEKK)	320 °F/160 °C	Process temp - 700 °F/371 °C	Outstanding chemical resistance Designed for structural applications Slightly lower processing temperature compared to PEEK	See data sheet for details.
Film Adhesives
TC235SF-1	Epoxy Surfacing Film	246 °F/119 °C	60 minutes at 250 °F/121 °C	Vacuum cure epoxy composite surfacing film Available with lightning strike foils	Excellent surfacing under low cure pressure
TC263 NEW	Epoxy	230 °F/110 °C	120 minutes at 250 °F/121 °C	Toughened film adhesive	21 days tack life
TC310 NEW	Epoxy	315 °F/157 °C	120 minutes at 350 °F/177 °C	Toughened composite bonding film adhesive	21 days tack life
TC4015	Cyanate Ester	350 °F/177 °C or 610 °F/321 °C with post cure	120 minutes at 350 °F/177 °C	Ablative structure High temp structure Space structure	14 days tack life
Syntactics
EM-3	Epoxy	N/A	60 minutes at 250 °F/121 °C	High expansion 250 °F/121 °C curing syntactic film Expansion of up to 8-10x	40 pcf (0.64 g/cc) unexpanded density
Toray Amspand ES72A-2	Epoxy	237 °F/114 °C (DSC)	60 minutes at 257 °F/125 °C	Expanding syntactic core Ideal for core splicing or core fill and edge close out applications Density of 6-25 pcf (0.1-0.4 g/cc)	30 days out life at 68 °F/20 °C
SF-4	BMI	563 °F/295 °C	120 minutes at 400 °F/204 °C and 360 minutes at 452 °F/250 °C	Compatible with RS-8HT and other BMI systems	Low density syntactic film 39 pcf (0.62 g/cc)
TCF4001	Cyanate Ester	350 °F/177 °C	120 minutes at 350 °F/177 °C Optional post cure of 60-90 minutes at 450 °F/232 °C	Cyanate ester syntactic paste Density of 24 pcf (0.38 g/cc)	14 days out life at 77 °F/25 °C
TCF4035	Epoxy	284 °F/140 °C	180 minutes at 265 °F/130 °C	Good high temperature properties Low density, low dielectric core fill Density of 40 pcf (0.64 g/cc) May be post cured for higher T_g	30 days out life at 77 °F/25 °C
TCF4045 NEW	Epoxy	356 °F/180 °C	180 minutes at 355 °F/179 °C	Excellent low dielectric syntactic film	35.5 pcf density (0.56 g/cc)
TCF4050	Cyanate Ester	350 °F/177 °C	120 minutes at 350 °F/177 °C Optional post cure of 60-90 minutes at 450 °F/232 °C	Density of 17-35 pcf (0.28-0.55g/cc) Expanding syntactic film (core splice) High temperature capability Compatible with TC420 prepreg systems	7 days out life at 77 °F/25 °C
RTM Resins
EX-1510	Cyanate Ester	380 °F/193 °C or 447 °F/230 °C with post cure	120 minutes at 350 °F/177 °C Optional post cure of 120 minutes at 480 °F/249 °C	Toughened resin system, low 150 cps viscosity at 77 °F/25 °C Low moisture absorption Good mechanical properties, good high temp performance	4 hours pot life at 77 °F/25 °C
RS-50	Epoxy	397 °F/203 °C	120 minutes at 350 °F/177 °C	Toughened epoxy resin for structural applications	30 minutes set time at 350 °F/177 °C

Figure 1. Applications of thermoplastic and thermoset composites

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This information has been sourced, reviewed and adapted from materials provided by Toray Advanced Composites.

For more information on this source, please visit Toray Advanced Composites.

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