Manufacturing of thermoplastic composite sandwich structures

2016 ◽  
Vol 30 (4) ◽  
pp. 437-464 ◽  
Author(s):  
Jonas Grünewald ◽  
Patricia Parlevliet ◽  
Volker Altstädt
Keyword(s):  
Adhesive Bonding ◽  
Sandwich Structures ◽  
Thermoplastic Composite ◽  
Aviation Industry ◽  
Compression Moulding ◽  
Fusion Bonding ◽  
Composite Sandwich ◽  
Composite Sandwich Structures ◽  
Vacuum Moulding

Composite sandwich structures show promising lightweight properties for the aviation industry. Nowadays time-consuming manufacturing methods still prevent an extensive application of composite sandwiches, which can be overcome by the use of thermoplastic polymers in skins and core. During manufacturing of thermoplastic composite (TPC) sandwich structures, the joining of skins and core is a critical step. Therefore, several skin–core joining methods have been under investigation and development in the published literature, which can be categorized into adhesive bonding or fusion bonding. Fusion bonding by means of vacuum moulding, compression moulding or in situ foaming shows great potential for joining sandwich skins and core. Although various phenomena such as core collapsing or skin deconsolidation challenge the processes. This article aims to present an overview of research that has been done in the area of manufacturing TPC sandwich structures and will serve as a baseline and aid for further research and development efforts.

Mechanical performance of CF/PEEK–PEI foam core sandwich structures

2017 ◽  
Vol 21 (8) ◽  
pp. 2680-2699 ◽  
Author(s):  
Jonas Grünewald ◽  
Patricia P Parlevliet ◽  
Alexander Matschinski ◽  
Volker Altstädt
Keyword(s):  
Mechanical Performance ◽  
Sandwich Structures ◽  
Cell Structure ◽  
Processing Parameters ◽  
Thermoplastic Composite ◽  
Composite Sandwich ◽  
The Core ◽  
Composite Sandwich Structures ◽  
Cell Structures ◽  
Original Cell

Previous work showed that thermoplastic composite sandwich structures offer great potential to meet the demands of lightweight structures for aviation applications. In this study, the influence of several processing parameters on the mechanical properties of thermoplastic sandwich components, consisting of carbon fibre reinforced polyetheretherketone skins and polyetherimide foam cores, is characterised. Sandwich specimens are manufactured with varying skin temperatures, core compaction distances and different polyetherimide concentrations at the skin–core interface. Following, sandwich samples are mechanically tested to characterise the bond strength, the core performance as well as the performance of the whole sandwich. The results show that in most cases the processing parameters significantly affect the cell structure of the sandwich core, provided that a proper fusion bond between skins and core exists. Thereby, the core performance seems to be weakened and failure predominantly occurs in the transition between affected and original cell structures.

scholarly journals In-situ repair of composite sandwich structures using cyanoacrylates

2016 ◽  
Vol 87 ◽  
pp. 203-211 ◽  
Author(s):  
Jack F. Cullinan ◽  
Paul Velut ◽  
Veronique Michaud ◽  
Michael R. Wisnom ◽  
Ian P. Bond
Keyword(s):  
Sandwich Structures ◽  
Composite Sandwich ◽  
Composite Sandwich Structures ◽  
In Situ Repair

Modified foam cores for full thermoplastic composite sandwich structures

2017 ◽  
Vol 21 (3) ◽  
pp. 1150-1166
Author(s):  
Jonas Grünewald ◽  
Tilman Orth ◽  
Patricia Parlevliet ◽  
Volker Altstädt
Keyword(s):  
Mechanical Performance ◽  
State Of The Art ◽  
Sandwich Structures ◽  
Thermoplastic Composite ◽  
Foam Core ◽  
Cycle Times ◽  
Composite Sandwich ◽  
Current State ◽  
Composite Sandwich Structures ◽  
Honeycomb Cores

Full thermoplastic composite sandwich structures with a foam core offer the possibility to be manufactured by fusion bonding in significant shorter cycle times than thermoset-based sandwiches. However, the application of foam cores results in lower mechanical properties such as compression and shear strength compared to honeycomb cores, therefore foam-based sandwiches cannot compete with sandwich structures based on Aramid/phenolic honeycomb cores, the current state of the art. In order to improve the mechanical performance of foam core-based sandwiches while maintaining their advantages, concepts to reinforce the foams were developed in this study. By introducing rods either orthogonally or diagonally to the skin plane, which are fusion bonded to the skins during processing, the compression and shear properties can be improved by up to 1000% and 72%, respectively. Even when correcting for the weight increase, an improved specific compression strength could be achieved. And therefore, the pinning looks especially promising when only applied locally in highly loaded areas for example.

scholarly journals The energy absorption behavior of novel composite sandwich structures reinforced with trapezoidal latticed webs

2021 ◽  
Vol 60 (1) ◽  
pp. 503-518
Author(s):  
Juan Han ◽  
Lu Zhu ◽  
Hai Fang ◽  
Jian Wang ◽  
Peng Wu
Keyword(s):  
Bearing Capacity ◽  
Energy Absorption ◽  
Sandwich Structure ◽  
Ultimate Load ◽  
Sandwich Structures ◽  
Elastic Displacement ◽  
Load Bearing Capacity ◽  
Load Bearing ◽  
Composite Sandwich ◽  
Composite Sandwich Structures

Abstract This article proposed an innovative composite sandwich structure reinforced with trapezoidal latticed webs with angles of 45°, 60° and 75°. Four specimens were conducted according to quasi-static compression methods to investigate the compressive behavior of the novel composite structures. The experimental results indicated that the specimen with 45° trapezoidal latticed webs showed the most excellent energy absorption ability, which was about 2.5 times of the structures with vertical latticed webs. Compared to the traditional composite sandwich structure, the elastic displacement and ultimate load-bearing capacity of the specimen with 45° trapezoidal latticed webs were increased by 624.1 and 439.8%, respectively. Numerical analysis of the composite sandwich structures was carried out by using a nonlinear explicit finite element (FE) software ANSYS/LS-DYNA. The influence of the thickness of face sheets, lattice webs and foam density on the elastic ultimate load-bearing capacity, the elastic displacement and initial stiffness was analyzed. This innovative composite bumper device for bridge pier protection against ship collision was simulated to verify its performance. The results showed that the peak impact force of the composite anti-collision device with 45° trapezoidal latticed webs would be reduced by 17.3%, and the time duration will be prolonged by about 31.1%.

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