Modelling and analysis of the thermal characteristic of thermoplastic composites from hybrid textiles during compression moulding

2019 ◽  
pp. 089270571987520
Author(s):  
Maximilian Koerdt ◽  
Michael Koerdt ◽  
Tobias Grobrüg ◽  
Marco Skowronek ◽  
Axel S Herrmann
Keyword(s):  
Optical Sensors ◽  
Thermal State ◽  
Process Analysis ◽  
Thermal Characteristic ◽  
Thermoplastic Composites ◽  
Compression Moulding ◽  
Cycle Times ◽  
Reinforced Plastics ◽  
Thermoset Resin ◽  
Thermoplastic Matrix

A promising strategy to decrease cycle times for manufacturing continuous-fibre–reinforced composites is processing of thermoplastic matrix systems due to their fast processability, since no cross-linking of molecular chains is required as for thermoset resin systems. Nevertheless, thermoplastic carbon fibre-reinforced plastics nowadays are predominantly manufactured with pre-impregnated sheet materials, which result in limited drapability and freedom of design. Hybrid textiles, consisting of thermoplastic and carbon fibres, can avoid these disadvantages. This class of reinforcements combines the drapability of dry textiles with thermoplastic matrices, which furthermore allow near net-shape processes. Relative shifting between the fibres and, consequently, draping is possible in a preforming step. The objective of this article is to expand our knowledge about hybrid textiles with regard to their thermal behaviour during compression moulding. Accordingly, the necessary parameters for modelling the thermal state of the dry textile and the impregnated laminate are investigated. Moreover, an in situ process analysis based on the reflection spectra of glass fibre-optical sensors, which are embedded inside the stacking, is investigated to provide information about the state of aggregation and to validate the thermal model.

Thermoactivated Pinning - A Novel Joining Technique for Thermoplastic Composites

2012 ◽  
Vol 188 ◽  
pp. 176-181 ◽  
Author(s):  
Werner Hufenbach ◽  
Robert Kupfer ◽  
Andreas Hornig
Keyword(s):  
Mechanical Properties ◽  
High Volume ◽  
Tensile Tests ◽  
Thermoplastic Composites ◽  
Structural Effects ◽  
Short Cycle ◽  
Cycle Times ◽  
Lap Shear ◽  
Thermoplastic Matrix ◽  
Manufacturing Techniques

Due to their good mechanical properties and short cycle times during processing, textile-reinforced thermoplastic composites gain increasing relevance for high-volume lightweight applications. Beyond that, by exploiting its specific processing capabilities, this composite material enables a variety of novel manufacturing techniques, e.g. for assembling. In this paper a joining technique is presented, which utilises the meltability of the thermoplastic matrix to establish a material-adapted joining method by introducing slender metallic pins into the composite structure. The processing principle is described and structural effects in the joining zone are analysed by means of microscopy. The load bearing behaviour is characterised by tensile tests on double-lap-shear specimen.

Mechanical Properties of Thermoplastic Composites via In Situ Polymerization from Cyclic Oligomers

2013 ◽  
Vol 750-752 ◽  
pp. 7-10
Author(s):  
Kou An Hao ◽  
Zhen Qing Wang ◽  
Li Min Zhou
Keyword(s):  
Mechanical Properties ◽  
In Situ Polymerization ◽  
High Viscosity ◽  
Thermoplastic Composites ◽  
Thermoplastic Matrix ◽  
Polymerization Catalyst ◽  
Short Beam ◽  
Beam Shear ◽  
Cyclic Oligomers

Fiber impregnation has been the main obstacle for thermoplastic matrix with high viscosity. This problem could be surmounted by adapting low viscous polymeric precursors Woven basalt fabric reinforced poly (butylenes terephthalate) composites were produced via in-situ polymerization at T=210°C. Before polymerization, catalyst was introduced to the reinforcement surface with different concentration. DSC is used to determine the polymerization and crystallization. SEM is used to detect whether the catalyst existed on surface. Both flexural and short-beam shear test are employed to study the corresponding mechanical properties.

scholarly journals Mechanical Properties of Compression Moulded Aggregate-Reinforced Thermoplastic Composite Scrap

2021 ◽  
Vol 5 (11) ◽  
pp. 299
Author(s):  
Julien Moothoo ◽  
Mahadev Bar ◽  
Pierre Ouagne
Keyword(s):  
Mechanical Properties ◽  
Tensile Properties ◽  
Test Method ◽  
Thermoplastic Composite ◽  
Recycled Aggregate ◽  
Thermoplastic Composites ◽  
Mechanical Recycling ◽  
Compression Moulding ◽  
Grain Sizes ◽  
Recycled Composites

Recycling of thermoplastic composites has drawn a considerable attention in the recent years. However, the main issue with recycled composites is their inferior mechanical properties compared to the virgin ones. In this present study, an alternative route to the traditional mechanical recycling technique of thermoplastic composites has been investigated with the view to increase mechanical properties of the recycled parts. In this regard, the glass/polypropylene laminate offcuts are cut in different grain sizes and processed in bulk form, using compression moulding. Further, the effect of different grain sizes (i.e., different lengths, widths and thicknesses) and other process-related parameters (such as mould coverage) on the tensile properties of recycled aggregate-reinforced composites have been investigated. The tensile properties of all composite samples are tested according to ISO 527-4 test method and the significance of test results is evaluated according to Student’s t-test and Fisher’s F-test respectively. It is observed that the tensile moduli of the recycled panels are close to the equivalent quasi-isotropic continuous fibre-reinforced reference laminate while there is a noteworthy difference in the strengths of the recycled composites. At this stage, the manufactured recycled composites show potential for stiffness-driven application.

The Hybrid Compression Moulding of Structural Composite Materials for Automotive Applications

2020 ◽  
Vol 843 ◽  
pp. 3-8 ◽  
Author(s):  
Helena C. Simmonds ◽  
Neil C. Reynolds ◽  
Kenneth N. Kendall
Keyword(s):  
Composite Materials ◽  
Manufacturing Process ◽  
Fibre Composite ◽  
Material Design ◽  
High Volume ◽  
Ford Motor Company ◽  
Compression Moulding ◽  
Cycle Times ◽  
Class Project ◽  
Automotive Suspension

The Innovate-UK-funded Composite Lightweight Automotive Suspension System (CLASS) project, led by Ford Motor Company and partnered by Gestamp UK, GRM Consulting and WMG, investigated the use of carbon fibre reinforced composite materials to decrease the weight of a complex automotive rear suspension component in support of reduction in vehicle emissions. A multi-material design comprising discontinuous fibre composite (C-SMC), aligned fibre composite laminate (prepreg) and steel was developed. A high volume hybrid compression moulding manufacturing process was developed at WMG, achieving total press cycle times of around 5 minutes. Prototype parts were manufactured and evaluated using materials characterisation techniques to validate the manufacturing methods. The optimum C-SMC charge pattern was investigated to achieve complete fill with minimal pre-processing. Destructive and nondestructive analysis of the hybrid parts was performed to understand resultant hybrid material macrostructure. This innovative design and manufacturing process resulted in a component 35% lighter than the original multi-piece steel design.

Z-pin insertion process for through-thickness reinforced thermoplastic composites

2018 ◽  
Vol 53 (2) ◽  
pp. 173-181 ◽  
Author(s):  
Julian Hoffmann ◽  
Alexander Brast ◽  
Gerhard Scharr
Keyword(s):  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Fiber Waviness ◽  
Reinforced Plastics ◽  
Pullout Tests ◽  
Glass Fiber Reinforced ◽  
Reinforced Plastic ◽  
Novel Method ◽  
Fiber Reinforced Plastics ◽  
Insertion Process

This paper presents a novel method for the ultrasonically assisted insertion of metallic z-pins into thermoplastic composites. Mechanical and microstructural investigations were carried out on glass fiber-reinforced polyamide and polypropylene specimens. The insertion of steel pins into thermoplastic composites led to microstructural changes that differ significantly from the known microstructure of z-pinned thermoset fiber-reinforced plastics. Optical microscopy showed an absence of notable fiber waviness and resin-rich zones around each pin. Instead, the fibers were predominantly deflected in the through-thickness direction by the high insertion forces arising during pin penetration. To gain an initial insight on the resulting properties of the z-pin/thermoplastic interface, the mechanical properties of z-pinned thermoplastic composites under mode I loading were investigated using pullout tests. For reference, the pullout behavior of thermoset carbon fiber-reinforced plastic specimens, reinforced with steel pins was determined too. Due to the poor bonding and lack of friction between the pin and laminate, the determined traction loads of the thermoplastic specimens are well below typical values achieved from pin pullout in thermoset laminates.

scholarly journals 3D Printing of Fibre-Reinforced Thermoplastic Composites Using Fused Filament Fabrication—A Review

Polymers ◽  
2020 ◽  
Vol 12 (10) ◽  
pp. 2188
Author(s):  
Andrew N. Dickson ◽  
Hisham M. Abourayana ◽  
Denis P. Dowling
Keyword(s):  
3D Printing ◽  
Polymer Composites ◽  
Mechanical Performance ◽  
Polymer Processing ◽  
Thermoplastic Composites ◽  
Fused Filament Fabrication ◽  
Compression Moulding ◽  
Processing Technologies ◽  
Reinforced Polymer ◽  
Fibre Reinforced Polymer

Three-dimensional (3D) printing has been successfully applied for the fabrication of polymer components ranging from prototypes to final products. An issue, however, is that the resulting 3D printed parts exhibit inferior mechanical performance to parts fabricated using conventional polymer processing technologies, such as compression moulding. The addition of fibres and other materials into the polymer matrix to form a composite can yield a significant enhancement in the structural strength of printed polymer parts. This review focuses on the enhanced mechanical performance obtained through the printing of fibre-reinforced polymer composites, using the fused filament fabrication (FFF) 3D printing technique. The uses of both short and continuous fibre-reinforced polymer composites are reviewed. Finally, examples of some applications of FFF printed polymer composites using robotic processes are highlighted.

scholarly journals Joule heating of dry textiles made of recycled carbon fibers and PA6 for the series production of thermoplastic composites

2020 ◽  
Vol 15 ◽  
pp. 155892502090582 ◽  
Author(s):  
Julian Reese ◽  
Michael Vorhof ◽  
Gerald Hoffmann ◽  
Kurt Böhme ◽  
Chokri Cherif
Keyword(s):  
Carbon Fibers ◽  
Joule Heating ◽  
Thermoplastic Composites ◽  
Fiber Direction ◽  
Molding Process ◽  
Transverse Fiber ◽  
Hybrid Yarn ◽  
Thermoplastic Matrix ◽  
One Step ◽  
Macroscopic Parameters

Processing carbon fiber reinforced thermoplastic parts includes heating to form the thermoplastic matrix. The needed heat can be applied externally or internally to the preform. One possibility to generate intrinsic heat involves the use of carbon fibers as a resistive element to induce joule heat. So far, most research efforts have been based on contacting continuous carbon fibers on both ends to melt the thermoplastic matrix of a pre-impregnated preform. The objective of this project is to use a dry hybrid yarn textile in a one-step process to impregnate and rapidly consolidate the dry textile in less than a minute. The desired molding process is based on joule heating of carbon fibers due to an applied current in the transverse fiber direction. This article focuses on the detection of the involved macroscopic parameters. The first composites produced by means of this new method exhibit a high potential with heating times of 15 s, a void fraction below 1%, and flexural properties comparable to the state of the art.

Research on Hot State of Mould Copper Plate with High Casting Speed

2011 ◽  
Vol 337 ◽  
pp. 214-218
Author(s):  
Li Gen Sun ◽  
Hui Rong Li ◽  
Jia Quan Zhang
Keyword(s):  
Casting Speed ◽  
Distribution Curve ◽  
Thermal State ◽  
Process Analysis ◽  
Great Influence ◽  
Equivalent Strain ◽  
Copper Plate ◽  
Steel Shell ◽  
High Casting Speed ◽  
Strain Stress

High casting speed has a great influence to thermal state and strain/stress field of the mould copper plate. The coupled visco-elasto-plastic FEM models have been presented for thermal process analysis of steel shell and the mould copper plates. It is shown that, when the casting speed is increasing, the turning point of the temperature distribution curve is getting further to the meniscus; and the increasing casting speed has no influence to the equivalent strain distribution along the thickness direction of the mould.

scholarly journals Unidirectional Carbon Fiber Reinforced Thermoplastic Tape in Automated Tape Placement Process

2021 ◽  
Author(s):  
Svetlana Risteska
Keyword(s):  
Mechanical Performance ◽  
Industrial Applications ◽  
Thermoplastic Composites ◽  
Matrix Composites ◽  
Fiber Reinforced ◽  
Consolidation Process ◽  
Heating And Cooling ◽  
Thermoplastic Matrix ◽  
New Applications ◽  
Process Ability

Thermoplastic matrix composites are finding new applications in the different industrial areas, thanks to their intrinsic advantages related to environmental compatibility and process-ability. The tape placement process is one of the few techniques that have the potential to continuously process thermoplastic composites in large industrial applications. Fiber-reinforced thermoplastic tapes are subjected to high heating and cooling rates during the tape placement process. The application of laser heating for the tape placement process requires a thorough understanding of the factors involved in the process. Qualitative experimental analysis is presented to identify the important phenomena during the tape placement of carbon (PEEK, PEKK, PAEK PPS) tapes. The present chapter focuses on the input parameters in the process of manufacturing composite parts. The mechanical performance of the final parts depend on a number of parameters. It should be void-free and well consolidated for reliable use in the structure. In the present work, it is becoming increasingly wiser to introduce the production of high-quality laminates, using laser AFP and ATL with quality consolidation during the laying process. The experimental results in this chapter help to better understand the consolidation process during LATP.

scholarly journals Fabrication of Fiber Reinforced Plastics by Ultrasonic Welding

2018 ◽  
Vol 2 (3) ◽  
pp. 56
Author(s):  
Andreas Gomer ◽  
Wei Zou ◽  
Niels Grigat ◽  
Johannes Sackmann ◽  
Werner Schomburg
Keyword(s):  
Carbon Fiber ◽  
Large Scale ◽  
Raw Materials ◽  
Glass Fibers ◽  
Ultrasonic Welding ◽  
Scale Production ◽  
Fiber Reinforced ◽  
Cycle Times ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics

Ultrasonic fabrication of fiber reinforced plastics made from thermoplastic polymer films and carbon or glass fibers enables cycle times of a few seconds and requires investment costs of only some 10,000 €. Besides this, the raw materials can be stored at room temperature. A fiber content of 33 vol % and a tensile strength of approximately 1.2 GPa have been achieved by ultrasonic welding of nine layers of foils from polyamide, each 100 µm in thickness, and eight layers of carbon fibers, each 100 µm in thickness, in between. Besides unidirectional carbon fiber reinforced polymer composite (CFRP) samples, multi-directional CFRP plates, 116 mm, 64 mm and 1.2 mm in length, width and thickness respectively, were fabricated by processing three layers of carbon fiber canvas, each 300 µm in thickness, and eight layers of polyamide foils, each 100 µm in thickness. Furthermore, both the discontinuous and the continuous ultrasonic fabrication processes are described and the results are presented in this paper. Large-scale production still needs to be demonstrated.

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