Manufacturing of a Composite Tailcone for an XM-1002 Training Round

Report No. ARL-TR-4381
Authors: James M. Sands; Uday Vaidya; George Husman; Juan Serrano; Robert Brannon
Date/Pages: February 2008; 22 pages
Abstract: Recent work on the cost-effective manufacturing of an extrusion-compression molded, long-fiber thermoplastic (LFT) XM 1002 tailcone for training rounds of military ammunition is compiled in this technical report. During the last decade, the engineering community has expanded the use of thermoplastic composites due to their inherent advantages over traditional thermoset composites including: high toughness, inexpensive resin systems, short processing cycle times, recycling potential, excellent environmental resistance, and damage tolerance. Thermoplastic composites have a wide range of applications in the automotive and transportation industry for replacement of heavy metal components and/or structures. LFT composites are a family of compounds with reinforcing fiber strands (fiber lengths typically range from 6 to 24 mm) combined with a thermoplastic matrix (which can be any commodity or engineering thermoplastic polymer). LFTs have the ability to be molded into complex geometries featuring ribs, knock-outs, and thickness variations within the parts. LFT parts/components can be processed by extrusion-compression, injection-compression, and/or injection-molding processes.
Distribution: Approved for public release
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Last Update / Reviewed: February 1, 2008