Manufacturing Process Development of a Thermoplastic Matrix Composite Horizontal Stabilizer

Manufacturing methods for a thermoplastic matrix composite horizontal stabilizer in support of Bell Helicopter Textron’s fusion bonded horizontal stabilizer program were developed concurrently with the design and testing of the horizontal stabilizer. This allowed the incorporation of the appropriate manufacturing techniques and material forms into the structure design. The horizontal stabilizer was designed to use carbon fiber reinforced PEEK (polyetheretherketone) for the entire structure. Internal components including two spars, trailing edge and ribs were manufactured by a variety of methods, primarily in-situ thermoplastic fiber placement and injection molding. The skin was fabricated using the in-situ thermoplastic fiber placement process using low cost aluminum tooling. This tooling both positioned and held the internal structure of the stabilizer, while leaving the flanges of individual components exposed. The skin was then integrally melt-bonded to the internal structure, as it was fiber placed. This paper describes the manufacturing techniques required for the fabrication of this horizontal stabilizer, including tooling considerations, processing conditions and design limitations due to manufacturing.