Development of pre-molded internal thread on composite tubes

Premolded internal threads on composite tubes were developed. The composite tubes with threads on both ends were made using a mandrel with a male thread. The threads can be applied to struts with adjustable end fits and composite pressure vessels with threaded caps that enable disassembly for inspection and repair. Carbon fiber-reinforced plastic (CFRP) prepregs were laid up on a mandrel, wrapped with shrink tape, and cured in an oven. The threads were built-in, without using machine cutting, and the fibers on the thread were continuous through the thread and tubes for high strength. The thread was alternately rounded, convex, and concave in shape to enable CFRP prepregs to be laid up. Two types of specimen were made and tested. The layup sequence of specimen A was [0/h/90/h/0/h(1/2)]s, and that of specimen B was [0/h/90/h/90/h/0/h/90/h/90/h/90/h/90/h/0/h/90/90/0], where “h” denotes a helical layer along the concave part of the threads. The relation between load and strain is nonlinear because of the rounded shape of the threads; however, a simple and closed form analytical model was able to predict the strength of the threads and design of the threads. The model was compared with the experimental results. In addition, an application of threads for the pressure vessel of the hybrid rocket motor is also reported. The combustion test proceeded without failure. Visual inspection after the test indicated that the threads and tubes were not damaged, and thus, they can be applied to high-pressure and high-temperature rocket motors.