A FAST METHOD FOR EVALUATING EFFECTS OF PROCESS PARAMETERS ON MORPHOLOGY OF SEMI-CRYSTALLINE THERMOPLASTIC COMPOSITES

2021 ◽  
Author(s):  
MATHEW WYNN ◽  
NAVID ZOBEIRY
Keyword(s):  
Carbon Fibers ◽  
Process Parameters ◽  
Processing Parameters ◽  
Crystal Nucleation ◽  
Thermoplastic Composites ◽  
Temperature Cycle ◽  
Fast Method ◽  
Contributing Factors ◽  
Fast Evaluation ◽  
Thin Glass

Semi-crystalline thermoplastics such as PEEK have microstructures that are influenced by process parameters like temperature cycle, humidity, and oxygen levels. Inclusions such as carbon fibers lead to heterogenous crystal nucleation. Further, manufacturing uncertainties involved with techniques such as automated fiber placement, compression molding, or induction welding influence the microstructure of thermoplastic composites. These contributing factors impact type (e.g., spherulitic, cross-linked, transcrystalline, and needle-like), size and distribution of morphologies in the material. Even with similar degrees of crystallinities, these differences affect mechanical properties and overall performance of composite parts. In this study, an experimental method has been developed that allows for fast evaluation of morphology as a function of process parameters in semi-crystalline thermoplastic composites. A compression fixture in a Dynamic Mechanical Analyzer (DMA) is used to process thin films of thermoplastics with embedded carbon fibers, sandwiched between thin glass covers, while carefully controlling processing conditions including temperature, pressure, and strain rate. The sample morphology is then analyzed using through transmission Polarizing Light Microscopy (PLM). Samples can be reprocessed using DMA several times to analyze changes in microstructure. This experimental approach allows for fast exploration of timetemperature- transformation relationships and their effects on morphology. This can be used to enhance our understanding of the material microstructure and develop more accurate process simulation tools, leading to optimization of processing parameters.

scholarly journals Review: Filament Winding and Automated Fiber Placement with In Situ Consolidation for Fiber Reinforced Thermoplastic Polymer Composites

Polymers ◽  
2021 ◽  
Vol 13 (12) ◽  
pp. 1951
Author(s):  
Yi Di Boon ◽  
Sunil Chandrakant Joshi ◽  
Somen Kumar Bhudolia
Keyword(s):  
Processing Parameters ◽  
Filament Winding ◽  
Reference Points ◽  
Thermoplastic Composites ◽  
Manufacturing Processes ◽  
Fiber Reinforced ◽  
Consolidation Process ◽  
Fiber Placement ◽  
Automated Fiber Placement

Fiber reinforced thermoplastic composites are gaining popularity in many industries due to their short consolidation cycles, among other advantages over thermoset-based composites. Computer aided manufacturing processes, such as filament winding and automated fiber placement, have been used conventionally for thermoset-based composites. The automated processes can be adapted to include in situ consolidation for the fabrication of thermoplastic-based composites. In this paper, a detailed literature review on the factors affecting the in situ consolidation process is presented. The models used to study the various aspects of the in situ consolidation process are discussed. The processing parameters that gave good consolidation results in past studies are compiled and highlighted. The parameters can be used as reference points for future studies to further improve the automated manufacturing processes.

scholarly journals Fused Deposition Modelling of Fibre Reinforced Polymer Composites: A Parametric Review

2021 ◽  
Vol 5 (1) ◽  
pp. 29
Author(s):  
Narongkorn Krajangsawasdi ◽  
Lourens G. Blok ◽  
Ian Hamerton ◽  
Marco L. Longana ◽  
Benjamin K. S. Woods ◽  
...  
Keyword(s):  
Process Parameters ◽  
Mechanical Performance ◽  
Fibre Length ◽  
Processing Parameters ◽  
Thermoplastic Composite ◽  
Fused Deposition Modelling ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Fibre Reinforced Polymer ◽  
Printing Parameters

Fused deposition modelling (FDM) is a widely used additive layer manufacturing process that deposits thermoplastic material layer-by-layer to produce complex geometries within a short time. Increasingly, fibres are being used to reinforce thermoplastic filaments to improve mechanical performance. This paper reviews the available literature on fibre reinforced FDM to investigate how the mechanical, physical, and thermal properties of 3D-printed fibre reinforced thermoplastic composite materials are affected by printing parameters (e.g., printing speed, temperature, building principle, etc.) and constitutive materials properties, i.e., polymeric matrices, reinforcements, and additional materials. In particular, the reinforcement fibres are categorized in this review considering the different available types (e.g., carbon, glass, aramid, and natural), and obtainable architectures divided accordingly to the fibre length (nano, short, and continuous). The review attempts to distil the optimum processing parameters that could be deduced from across different studies by presenting graphically the relationship between process parameters and properties. This publication benefits the material developer who is investigating the process parameters to optimize the printing parameters of novel materials or looking for a good constituent combination to produce composite FDM filaments, thus helping to reduce material wastage and experimental time.

scholarly journals Optimizing Laser Powder Bed Fusion Parameters for IN-738LC by Response Surface Method

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4879
Author(s):  
Mireia Vilanova ◽  
Rubén Escribano-García ◽  
Teresa Guraya ◽  
Maria San Sebastian
Keyword(s):  
Response Surface ◽  
Response Surface Method ◽  
Process Parameters ◽  
Crack Density ◽  
Processing Parameters ◽  
Optimum Process ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Surface Method

A method to find the optimum process parameters for manufacturing nickel-based superalloy Inconel 738LC by laser powder bed fusion (LPBF) technology is presented. This material is known to form cracks during its processing by LPBF technology; thus, process parameters have to be optimized to get a high quality product. In this work, the objective of the optimization was to obtain samples with fewer pores and cracks. A design of experiments (DoE) technique was implemented to define the reduced set of samples. Each sample was manufactured by LPBF with a specific combination of laser power, laser scan speed, hatch distance and scan strategy parameters. Using the porosity and crack density results obtained from the DoE samples, quadratic models were fitted, which allowed identifying the optimal working point by applying the response surface method (RSM). Finally, five samples with the predicted optimal processing parameters were fabricated. The examination of these samples showed that it was possible to manufacture IN738LC samples free of cracks and with a porosity percentage below 0.1%. Therefore, it was demonstrated that RSM is suitable for obtaining optimum process parameters for IN738LC alloy manufacturing by LPBF technology.

scholarly journals Development of an Additive Manufacturing System for the Deposition of Thermoplastics Impregnated with Carbon Fibers

2019 ◽  
Vol 3 (2) ◽  
pp. 35 ◽  
Author(s):  
Miguel Reis Silva ◽  
António M. Pereira ◽  
Nuno Alves ◽  
Gonçalo Mateus ◽  
Artur Mateus ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Additive Manufacturing ◽  
Carbon Fibers ◽  
Low Cost ◽  
Deposition Process ◽  
Processing Parameters ◽  
Yarn Diameter ◽  
Thermoplastic Matrix ◽  
Anisotropic Mechanical Properties ◽  
Long Carbon Fiber

This work presents an innovative system that allows the oriented deposition of continuous fibers or long fibers, pre-impregnated or not, in a thermoplastic matrix. This system is used in an integrated way with the filamentary fusion additive manufacturing technology and allows a localized and oriented reinforcement of polymer components for advanced engineering applications at a low cost. To demonstrate the capabilities of the developed system, composite components of thermoplastic matrix (polyamide) reinforced with pre-impregnated long carbon fiber (carbon + polyamide), 1 K and 3 K, were processed and their tensile and flexural strength evaluated. It was demonstrated that the tensile strength value depends on the density of carbon fibers present in the composite, and that with the passage of 2 to 4 layers of fibers, an increase in breaking strength was obtained of about 366% and 325% for the 3 K and 1 K yarns, respectively. The increase of the fiber yarn diameter leads to higher values of tensile strength of the composite. The obtained standard deviation reveals that the deposition process gives rise to components with anisotropic mechanical properties and the need to optimize the processing parameters, especially those that lead to an increase in adhesion between deposited layers.

Interlaminar Fracture in Carbon Fiber/Thermoplastic Composites

1989 ◽  
Vol 170 ◽  
Author(s):  
J. A. Hinkley ◽  
W. D. Bascom ◽  
R. E. Allred
Keyword(s):  
Fracture Toughness ◽  
Carbon Fiber ◽  
Carbon Fibers ◽  
High Strain ◽  
Thermoplastic Composites ◽  
Plasma Modification ◽  
Interlaminar Fracture Toughness ◽  
Interlaminar Fracture ◽  
Polyphenylene Oxide ◽  
Commercial Carbon

AbstractThe surfaces of commercial carbon fibers are generally chemically cleaned or oxidized and then coated with an oligomeric sizing to optimize their adhesion to epoxy matrix resins. Evidence from fractography, from embedded fiber testing and from fracture energies suggests that these standard treatments are relatively ineffective for thermoplastic matrices. This evidence is reviewed and model thermoplastic composites (polyphenylene oxide/high strain carbon fibers) are used to demonstrate how differences in adhesion can lead to a two-fold change in interlaminar fracture toughness.The potential for improved adhesion via plasma modification of fiber surfaces is discussed. Finally, a surprising case of fiber-catalyzed resin degradation is described.

Warpage and Shrinkage Analysis and Optimization of Rapid Tooling Molded thin Wall Component Using Modified Particle Swarm Algorithm

2019 ◽  
Vol 18 (01) ◽  
pp. 85-102 ◽  
Author(s):  
Sagar Kumar ◽  
Amit Kumar Singh
Keyword(s):  
Injection Molding ◽  
Process Parameters ◽  
Simulation Analysis ◽  
Statistical Significance ◽  
Particle Swarm ◽  
Processing Parameters ◽  
Particle Swarm Algorithm ◽  
Thin Wall ◽  
Polybutylene Terephthalate ◽  
Melt Temperature

This paper presents a systematic methodology to determine optimal injection molding conditions for minimum warpage and shrinkage in a thin wall relay part using modified particle swarm optimization algorithm (MPSO). Polybutylene terephthalate (PBT) and polyethylene terephthalate (PET) were injected in a thin wall relay component for different processing parameters: melt temperature, packing pressure and packing time. Further, Taguchi’s L9 (3[Formula: see text] orthogonal array is used for conducting simulation analysis to consider the interaction effects of the above parameters. A predictive mathematical model for shrinkage and warpage is developed in terms of the above process parameters using regression analysis. ANOVA analysis is performed to establish statistical significance within the injection molding parameters. The analytical model is further optimized using a newly developed MPSO algorithm and the process parameters values are predicted for minimizing shrinkage and warpage. The predicted values of shrinkage and warpage using MPSO algorithm are improved by approximately 30% as compared to the initial simulation values and comparable to previous literature results.

An Experimental Determination of Optimum Processing Parameters for Al∕SiC Metal Matrix Composites Made Using Ultrasonic Consolidation

2007 ◽  
Vol 129 (4) ◽  
pp. 538-549 ◽  
Author(s):  
Y. Yang ◽  
G. D. Janaki Ram ◽  
B. E. Stucker
Keyword(s):  
Bond Strength ◽  
Metal Matrix Composites ◽  
Process Parameters ◽  
Metal Matrix ◽  
Oscillation Amplitude ◽  
Processing Parameters ◽  
Optimum Combination ◽  
Matrix Composites ◽  
Ultrasonic Consolidation ◽  
Push Out

Ultrasonic consolidation, an emerging additive manufacturing technology, is one of the most recent technologies considered for fabrication of metal matrix composites (MMCs). This study was performed to identify the optimum combination of processing parameters, including oscillation amplitude, welding speed, normal force, operating temperature, and fiber orientation, for manufacture of long-fiber-reinforced MMCs. A design of experiments approach (Taguchi L25 orthogonal array) was adopted to statistically determine the influences of individual process parameters. SiC fibers of 0.1mm diameter were successfully embedded into an Al 3003 metal matrix. Push-out testing was employed to evaluate the bond strength between the fiber and the matrix. Data from push-out tests and microstructural studies were analyzed and an optimum combination of parameters was achieved. The effects of process parameters on bond formation and fiber/matrix bond strength are discussed.

Modeling and Numerical Simulation of Laminated Thermoplastic Composites Manufactured by Laser-Assisted Automatic Tape Placement

2020 ◽  
Vol 35 (5) ◽  
pp. 471-480
Author(s):  
G. Ausias ◽  
G. Dolo ◽  
D. Cartié ◽  
F. Challois ◽  
P. Joyot ◽  
...  
Keyword(s):  
Temperature Distribution ◽  
Numerical Model ◽  
Pressure Field ◽  
Processing Parameters ◽  
Thermoplastic Composites ◽  
Final Thickness ◽  
Intimate Contact ◽  
Polymer Flow ◽  
Compaction Force ◽  
Heat Transfer Simulation

Abstract A comprehensive numerical model is developed for the simulation of the laser-assisted automated tape placement process of carbon fiber/thermoplastic composites. After being heated with a laser, the thermoplastic is welded with the help of a consolidation roller onto a substrate made up of layers of tapes bonded onto one another. Under the pressure applied by the roller, the thermoplastic flows and the tape reaches its final thickness. The numerical model is developed in three sequential steps that can be used to identify the required pressure and temperature distribution to achieve a good bond. Firstly, a heat transfer simulation is performed to determine the temperature distribution into the incoming tape under the consolidation roller. Secondly, a rheological model is developed to examine the polymer flow under the roller and to obtain the pressure field. Finally, the consolidation level between the substrate and the tape is investigated through the degree of intimate contact, which is related to the processing parameters such as the roller velocity, the laser power density and the compaction force.

scholarly journals Open-End Yarn Properties Prediction Using HVI Fibre Properties and Process Parameters

2017 ◽  
Vol 17 (1) ◽  
pp. 6-11 ◽  
Author(s):  
Hanen Ghanmi ◽  
Adel Ghith ◽  
Tarek Benameur
Keyword(s):  
Response Surface ◽  
Process Parameters ◽  
Processing Parameters ◽  
Raw Material ◽  
Spun Yarn ◽  
Yarn Properties ◽  
Spun Yarns ◽  
Yarn Count ◽  
Input Variables ◽  
Rotor Spun Yarn

AbstractThis article provides three models to predict rotor spun yarn characteristics which are breaking strength, breaking elongation and unevenness. These models used noncorrelated raw material characteristics and some processing parameters. For this purpose, five different cotton blends were processed into rotor spun yarns having different metric numbers (Nm10, Nm15, Nm18, Nm22, Nm30 and Nm37). Each count was spun at different twist levels. Response surface method was used to estimate yarn quality characteristics and to study variable effects on these characteristics. In this study, predicting models are given by the analysis of response surface after many iterations in which nonsignificant terms are excluded for more accuracy and precision. It was shown that yarn count, twist and sliver properties had considerable effects on the open-end rotor spun yarn properties. This study can help industrial application since it allows a quality management-prediction based on input variables such as fibre characteristics and process parameters.

Sign in / Sign up

Export Citation Format

Share Document