Globe Composites | MOLDED COMPOSITE STRUCTURES

Compression Molding of Quartz Fiber Phenolic Components

In this project, an aerospace customer required compression molding of an insulated nut from ablative composites composed of super high temperature quartz fiber phenolic compound. This high performance ablative composite is used in an aerospace system to prevent encapsulated metallic components from melting during re-entry into the earth's atmosphere.

From the customer's specifications, Globe's design and engineering team went to work designing the hardened single cavity mold. They also provided complete fabrication of the mold as well as process development, which included precision compression molding that includes a nickel coated beryllium insert. An 80-ton compression molding system was used for the 305 gram shot that was subject to cavity pressures of 2,500 to 5,000 psi, before being finished with precision CNC machining. The finished component measured 3" in diameter and 1" in height, with a wall thickness that ranged from 0.050" - 1.00". A tight tolerance of ± 0.005" and shrinkage allowance of .00075" per inch was also achieved. All of which was verified through comprehensive visual and dimensional inspections as well as x-ray and other nondestructive testing.

This project is also in full compliance with AS 9100, various Mil Specs, and weapon specifications for ablative composites, and confirmed through the certificate of conformance (CoC) provided with each shipment. It is manufactured in quantities of up to 1000 units that are shipped annually to locations throughout the United States.

For more information about this aerospace insulated nut project, or any of Globe's critical components manufacturing capabilities, please see the table below or contact Globe directly.

Quartz Fiber Phenolic Component Project Details

Product Description
Ablative Composite Insulated Nut for Re-Entry
Compression Molding Capabilities Applied/Processes
Primary:
Engineering
  • Tooling Design
  • Tooling Fabrication
  • Process Development
Compression Molding - 1 Cavity
  • Shot Size: 305 ± 0.2 grams
Secondary:
CNC Machining
Equipment Used to Manufacture Part
80 Ton compression molding machine
Overall Part Dimensions
Product Length: 6.00"
Product Width: 2.00"
Product Height: 1.00"
Tightest Tolerances
± 0.005"
Shrinkage Allowance: .00075 inch per inch
Maximum Clamping Force: 2,500 to 5,000 psi cavity pressure
Material Used
Quartz Fiber Phenolic
Material Thickness: 0.050" - 1.00"
Material Finish
Color: Natural
Special Feature
Nickel Coated Beryllium Insert
In process testing/inspection performed
Non-Destructive Testing, Certificate of Conformance
Industry for Use
Aerospace
Volume
100 - 1000 Annually
Delivery Location
USA
Standards Met
Customer Specifications, 2D CAD Drawing
AS 9100
Mil Spec.
Weapon Specs.