Methods of manufacturing material systems

A method of manufacturing a material system, the method comprising:

• laying up a first layer adjacent to a mold tool;
• laying up a second layer adjacent to the first layer;
• laying up a third layer adjacent to the second layer;
• laying up a fourth layer adjacent to the third layer;
• and
• consolidating one or more thermoplastic prepreg plies of a first glass composite layer, a second glass composite layer, and a carbon composite layer;
• wherein the first, second, third, and fourth layers form a stack,
• wherein one of the first, second, third, and fourth layers comprises the carbon composite layer, and wherein another one of the first, second, third, and fourth layers comprises an aluminum layer,
• wherein another one of the first, second, third, and fourth layers comprises the first glass composite layer,
• wherein another one of the first, second, third, and fourth layers comprises the second glass composite layer,
• wherein at least one of the first glass composite layer and the second glass composite layer prevents interaction between the aluminum layer and the carbon composite layer,
• wherein the first glass composite layer comprises glass fibers, but no carbon fibers,
• wherein the second glass composite layer comprises glass fibers, but no carbon fibers,
• wherein the consolidating of the one or more thermoplastic prepreg plies of the first glass composite layer, the second glass composite layer, and the carbon composite layer comprises:
• raising a temperature of the stack to greater than or equal to 700° F. and less than or equal to 720° F.;
• raising a pressure of the stack to greater than or equal to 95 pounds per square inch gage (psig) and less than or equal to 105 psig;
• and
• holding the temperature and pressure of the stack for greater than or equal to 5 minutes and less than or equal to 15 minutes, and
• wherein the consolidating of the one or more thermoplastic prepreg plies of the first glass composite layer, the second glass composite layer, and the carbon composite layer comprises a heat-up phase wherein the pressure is low and the heat up rate is any value, a hold phase wherein the temperature is held substantially constant within 700° and 720° F. and the pressure is held substantially constant within 95 and 105 psig, and a cooldown phase wherein a temperature cooldown rate is limited and a pressure band is maintained until the temperature is significantly reduced.

A method of manufacturing a material system, the method comprising:

• laying up a first layer adjacent to a mold tool;
• laying up a second layer adjacent to the first layer;
• laying up a third layer adjacent to the second layer;
• laying up a fourth layer adjacent to the third layer;
• laying up a fifth layer adjacent to the fourth layer;
• and
• consolidating one or more thermoplastic prepreg plies of a first glass composite layer, a second glass composite layer, and one or more carbon composite layers;
• wherein the first, second, third, fourth, and fifth layers form a stack,
• wherein at least one of the first, second, third, fourth, and fifth layers comprises the one or more carbon composite layers, and wherein at least one of the first, second, third, fourth, and fifth layers comprises one or more aluminum layers,
• wherein one of the first, second, third, fourth, and fifth layers comprises the first glass composite layer,
• wherein one of the first, second, third, fourth, and fifth layers comprises the second glass composite layer,
• wherein at least one of the first glass composite layer and the second glass composite layer prevents interaction between the one or more aluminum layers and the one or more carbon composite layers,
• wherein the first glass composite layer comprises glass fibers, but no carbon fibers,
• wherein the second glass composite layer comprises glass fibers, but no carbon fibers,
• wherein the consolidating of the one or more thermoplastic prepreg plies of the first glass composite layer, the second glass composite layer, and the one or more carbon composite layers comprises:
• raising a temperature of the stack to greater than or equal to 700° F. and less than or equal to 720° F.;
• raising a pressure of the stack to greater than or equal to 95 pounds per square inch gage (psig) and less than or equal to 105 psig;
• and
• holding the temperature and pressure of the stack for greater than or equal to 5 minutes and less than or equal to 15 minutes, and
• wherein the consolidating of the one or more thermoplastic prepreg plies of the first glass composite layer, the second glass composite layer, and the one or more carbon composite layers comprises a heat-up phase wherein the pressure is low and the heat up rate is any value, a hold phase wherein the temperature is held substantially constant within 700° and 720° F. and the pressure is held substantially constant within 95 and 105 psig, and a cooldown phase wherein a temperature cooldown rate is limited and a pressure band is maintained until the temperature is significantly reduced.