scholarly journals The Effects of Processing Parameters on the Wedge Peel Strength of CF/PEEK Laminates Manufactured Using a Laser Tape Placement Process

2021 ◽  
Author(s):  
Chenping Zhang ◽  
Yugang Duan ◽  
Hong Xiao ◽  
Ben Wang ◽  
Yueke Ming ◽  
...  
Keyword(s):  
Cross Sections ◽  
Composite Laminates ◽  
Microscopic Analysis ◽  
Processing Parameters ◽  
Peel Strength ◽  
Thermoplastic Composites ◽  
Resin Matrix ◽  
Processing Temperature ◽  
Scanning Calorimetry ◽  
Automated Fiber Placement

Abstract Manufacturing thermoplastic composites (TPC) with excellent mechanical properties requires advanced methods with reduced costs and better overall efficiencies. In this study, fiber-reinforced thermoplastic polymer composite laminates were manufactured using an automated fiber placement (AFP) manufacturing technology. The effects of processing temperature (from 320 ℃ to 500 ℃), lay-up speed (from 20 mm/s to 260 mm/s), consolidation force (from 100 N to 600 N), and prepreg tape tension (from 0 N to 9 N) on the quality of the resulting laminates manufactured using the laser AFP system were investigated. The interlayer bond strength was characterized using wedge peel tests on samples prepared with different process parameters. The studies were complemented by measurements of the thermal properties of the composites using different scanning calorimetry. The optimized process parameter windows were determined to be 360 ℃ to 400 ℃ for the irradiation temperature, 140 mm/s to 160 mm/s for the lay-up speed, 100 N for the consolidation force, and 3 N to 5 N for the prepreg tape tension, respectively. The microscopic analysis of the cross-sections and peel-damaged surfaces revealed that the different distributions of the resin matrix resulting from the different processing parameters affected the interlayer strength. These results may provide an important reference for manufacturing TPC used in aerospace, defense, and automotive applications.

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.

Postprocessing method-induced mechanical properties of carbon fiber-reinforced thermoplastic composites

2020 ◽  
pp. 089270572094537
Author(s):  
Van-Tho Hoang ◽  
Bo-Seong Kwon ◽  
Jung-Won Sung ◽  
Hyeon-Seok Choe ◽  
Se-Woon Oh ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
Processing Parameters ◽  
Thermoplastic Composites ◽  
Void Content ◽  
Fiber Reinforced ◽  
Crystallinity Degree ◽  
Automated Fiber Placement ◽  
Carbon Fiber Reinforced

Promising carbon fiber-reinforced thermoplastic (CF/polyetherketoneketone (PEKK)) composites were fabricated by the state-of-the-art technology known as “Automated Fiber Placement.” The mechanical properties of CF/PEKK were evaluated for four different postprocessing methods: in situ consolidation, annealing, vacuum bag only (VBO), and hot press (HP). The evaluation was performed by narrowing down the relevant processing parameters (temperature and layup speed). Furthermore, the void content and crystallinity of CF/PEKK were measured to determine the effect of these postprocessing processes. The HP process resulted in the best quality with the highest interlaminar shear strength, highest crystallinity degree, and lowest void content. The second most effective method was VBO, and annealing also realized an improvement compared with in situ consolidation. The correlation between the postprocessing method and the void content and crystallinity degree was also discussed.

Pultrusion Technology Optimization for Hybrid Fiber Composites Based on DSC and Mechanical Property Testing

2011 ◽  
Vol 295-297 ◽  
pp. 383-387 ◽  
Author(s):  
Li Chen ◽  
Qi Lin Zhao ◽  
Ke Bin Jiang ◽  
Yong Ding
Keyword(s):  
Mechanical Properties ◽  
Fiber Composite ◽  
Processing Parameters ◽  
Fiber Composites ◽  
Processing Temperature ◽  
Processing Parameter ◽  
Heating Rates ◽  
Hybrid Fiber ◽  
Scanning Calorimetry ◽  
Parameter Ranges

In the interest of improving the curing effect and mechanical properties of pultruded carbon/glass bybrid fiber composites, the DSC (Differential Scanning Calorimetry) technology was introduced and the curing DSC curves for the hybrid fiber composites at 4 different heating rates was attained. Then the range of the processing temperature for the three-stage heating pultrusion was primarily determined with T-β method. Subsequently a kind of carbon/glass hybrid composite pole with a diameter of 11mm was selected as the research object, and was manufactured with varies of processing temperatures and speeds. The produced poles were mechanically tested to investigate the effect of processing parameters on the mechanical properties of the composite, so as to further more ascertain the processing parameter ranges fitting to this material formula. As the result shows: the pultrusion processing parameters for the hybrid fiber composite acquired in this study can satisfy the require of manufacturing; compared with the traditional method that attain processing parameters by experience, the method for attaining processing parameters suggested in this paper is more efficiency, more economical and more accurate.

Processing of thermoplastic matrix composites through automated fiber placement and tape laying methods

2017 ◽  
Vol 31 (12) ◽  
pp. 1676-1725 ◽  
Author(s):  
Khaled Yassin ◽  
Mehdi Hojjati
Keyword(s):  
Heat Transfer ◽  
Quality Parameters ◽  
Thermoplastic Composites ◽  
Transfer Model ◽  
Scanning Calorimetry ◽  
Intimate Contact ◽  
Fiber Placement ◽  
Hot Gas ◽  
Lap Shear ◽  
Automated Fiber Placement

Fiber-reinforced composite materials are replacing metallic components due to their higher specific strength and stiffness. Automation and thermoplastics emerged to overcome the time and labor intensive manual techniques and the long curing cycles associated with processing thermoset-based composites. Thermoplastics are processed through fusion bonding which involves applying heat and pressure at the interface. Together with automated techniques (such as automated fiber placement, and automated tape laying), a fast, clean, out-of-autoclave, and automated process can be obtained. A detailed review of thermoplastic composites processing through automated methods is presented. It sheds the light on the materials used and the different heat sources incorporated with the pros and cons of each, with concentration mainly on hot gas torch, laser, and ultrasonic heating. A thorough illustration of the several mechanisms involved in a tow/tape placement process is tackled such as heat transfer, intimate contact development, molecular interdiffusion, void consolidation and growth, thermal degradation, crystallization, and so on. Few gaps and recommendations are included related to materials, laser heat source, heat transfer model, and the use of silicone rubber rollers. A review of optimization studies for tape placement processes is summarized including the main controllable variables and product quality parameters (or responses), with some of the major findings for laser and hot gas torch systems being presented. Both mechanical and physical characterizations are also reviewed including several testing techniques such as short beam shear, double cantilever beam, lap shear, wedge peel, differential scanning calorimetry, and so on. Challenges, however, still exist, such as achieving the autoclave-level mechanical properties and complying with the porosity levels required by the aerospace industry. More work is still necessary to overcome these challenges as well as increase the throughput of the process before it can be totally commercialized.

Thermal Stability of Natural Fibers via Thermoset Coating for Application in Engineering Thermoplastics

2019 ◽  
Vol 809 ◽  
pp. 433-438 ◽  
Author(s):  
Natalie Vellguth ◽  
Tanja Rudeck ◽  
Madina Shamsuyeva ◽  
Franz Renz ◽  
Hans Josef Endres
Keyword(s):  
Mechanical Properties ◽  
Thermal Stability ◽  
Epoxy Resin ◽  
Natural Fiber ◽  
Natural Fibers ◽  
Thermoplastic Composites ◽  
Processing Temperature ◽  
Scanning Calorimetry ◽  
Flax Fibers ◽  
Thermal Stability Of

An effective integration of natural fibers into engineering thermoplastics requires sufficient thermal stability of natural fibers during processing, since melting temperature of engineering thermoplastics lies above 200 °C. The aim of the work was to protect natural fibers from the heat of the molten thermoplastic via coating with a modified epoxy resin, thus enabling manufacture of natural fiber-reinforced engineering thermoplastic composites with minimized thermal degradation of the fibers. Processing temperature comprised the range of engineering thermoplastic polyamide 6 (PA6), which was 225 °C. Flax fabrics were spray coated with partially bio-based epoxy resin and incorporated via hot press technique into a PA6 matrix. The composite samples including spray coated flax fibers as well as the reference flax fibers without coating were characterized with regard to their mechanical properties, namely bending and tensile tests, thermal properties with differential scanning calorimetry (DSC) as well as thermogravimetric analysis (TGA) and optical via scanning electron microscopy (SEM) and computer tomography (CT). The results show that this approach enables manufacture of composites with reproducible mechanical properties, i.e. bending and tensile properties as well as enhanced thermal stabilities.

scholarly journals Interlaminar adhesion assessment of carbon-epoxy laminates under salt water ageing using peel tests

2018 ◽  
Vol 233 (8) ◽  
pp. 1555-1563 ◽  
Author(s):  
Marcio M Arouche ◽  
Sandip Budhe ◽  
Mariana D Banea ◽  
Sofia Teixeira de Freitas ◽  
Silvio de Barros
Keyword(s):  
Composite Laminates ◽  
Salt Water ◽  
Chemical Characterization ◽  
Microscopic Analysis ◽  
Peel Test ◽  
Peel Strength ◽  
Water Tank ◽  
Electron Microscopic ◽  
Peel Tests ◽  
Fibre Matrix

The aim of this study is to assess the interlaminar adhesion of carbon-epoxy laminates under salt water condition. Carbon-epoxy laminate specimens were immersed in a salt water tank for 60 days. Some specimens were then dried at room temperature for 280 days, until recovering their initial weight. Specimens were tested using the composite peel test, an adaptation of the floating roller peel tests for composite materials. The results showed a degradation of peel strength in some areas due to the ageing process. The drying process did not affect the test results. A scanning electron microscopic analysis carried out on the fracture surface of the specimens revealed a typical mode I failure microstructure. A mixture of matrix failure and fibre/matrix interfacial failure was observed in non-aged specimens. Finally, a chemical characterization of the fracture surfaces with energy-dispersive spectroscopy confirmed the penetration of salt water in regions near the edge of the specimens. A degradation of the fibre/matrix interface adhesion was observed in affected areas. Floating roller peel tests proved to be a fast and effective method to access the interlaminar adhesion performance of composite laminates.

EFFECT OF PROCESSING PARAMETERS ON THE WIDTHS AND THICKNESSES OF THERMOPLASTIC COMPOSITES MADE BY AUTOMATED FIBER PLACEMENT

2021 ◽  
Author(s):  
DUC MINH HOANG ◽  
SUONG VAN HOA
Keyword(s):  
Applied Pressure ◽  
Processing Parameters ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Engineering Structures ◽  
Fiber Placement ◽  
Automated Fiber Placement ◽  
The Individual ◽  
Placement Machine ◽  
Curved Panels

The advent of Automated Fiber Placement (AFP) machine has expanded the capacities to manufacture engineering structures using thermoplastic composites. Structures of cylindrical shapes, flat and curved panels can be easily made using this technique. As more applications and more studies have been made on this technique for thermoplastic composites, many issues have come up. One issue of importance is the variation of the width and thickness of the tow as it is deposited. As the melted thermoplastic composite tow is being pressed under the compression force of the roller, the material flows. This changes the width and the thickness of the tow. The values of the width and thickness depend on many parameters such as the properties of the substrate, the temperature of the material, and the applied pressure. This variation in width and thickness of the individual tow being deposited has an influence on the development of laps and gaps between the deposited tows. This paper presents some of the results on an investigation on the above topic. Widths and thicknesses of carbon/PEEK tows processed using an Automated Fiber Placement machine with a hot gas torch were examined. Preliminary results show that there is significant variation in the width and thickness of the tows upon deposition.

Investigation and analysis of glass fabric/PVC composite laminates processing parameters

2018 ◽  
Vol 25 (3) ◽  
pp. 529-540 ◽  
Author(s):  
Vahid Zal ◽  
Hassan Moslemi Naeini ◽  
Ahmad Reza Bahramian ◽  
Amir Hossein Behravesh ◽  
Behnam Abbaszadeh
Keyword(s):  
Flexural Strength ◽  
Composite Laminates ◽  
Processing Time ◽  
Processing Parameters ◽  
Test Method ◽  
Bending Test ◽  
Maximum Effect ◽  
Processing Temperature ◽  
Matrix Degradation ◽  
The Matrix

Abstract In this work, the effects of processing parameters including temperature, time, and pressure on the properties of amorphous polyvinyl chloride (PVC)/fiberglass thermoplastic composite laminates were evaluated. The film stacking and hot pressing procedure was used to produce the composite laminates, and samples with [0/90]10 layup and thickness of 3 mm were produced. Flexural strength and modulus of the samples were measured using three-point bending test (according to ASTM D790 standard test method), and microscopic images were used to evaluate the failure mechanisms and impregnation quality. The effects of the parameters on the strength were studied using analysis of variance (ANOVA), and it was found that processing temperature has the maximum effect on the products strength and increase of the temperature up to 230°C increases the flexural strength while more increase of temperature results in the matrix degradation and strength reduction. Also, processing time improves the wetting and impregnation quality; however, more increase of the processing time results in the matrix degradation and excessive reduction of the strength.

A numerical analysis of an energy directing method through friction heating during the ultrasonic welding of thermoplastic composites

2019 ◽  
Vol 33 (11) ◽  
pp. 1569-1587 ◽  
Author(s):  
Shahan Tutunjian ◽  
Oguzhan Eroglu ◽  
Martin Dannemann ◽  
Niels Modler ◽  
Fabian Fischer
Keyword(s):  
Composite Laminates ◽  
Microscopic Analysis ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Vibration Energy ◽  
Additional Energy ◽  
Interfacial Layers ◽  
Spot Center ◽  
Friction Heating ◽  
A New Technique

The ultrasonic spot welding of fiber-reinforced thermoplastic laminates received a wide interest from researchers mainly in the fields of aerospace and automotive industries. This study investigated a new technique for focusing the ultrasonic vibration energy at the desired spot between two mating thermoplastic composite laminates. In this investigated method, no additional energy directing protrusions between the mating laminates were required to focus the vibration energy. It was found that by welding the laminates amid an ultrasonic horn and an anvil in which the prior had a larger contact surface with the laminate as the latter, it was possible to generate a localized friction heating. In the initial phase of the welding, the friction heating softened the interfacial layers and thus caused the focusing of the majority of the cyclic ultrasonic strain energy in the weld spot center. The assumption for the presence of the friction and its influence on the heat generation was investigated by means of finite element method (FEM) mechanical dynamic analysis. Microscopic analysis of the weld spot eventually delivered the proof for the melt initiation by friction at a ring around the weld spot and subsequent spot growth by viscoelastic heating.

Processing and characterization of the thermoplastic composites manufactured by ultrasonic vibration–assisted automated fiber placement

2017 ◽  
Vol 31 (3) ◽  
pp. 339-358 ◽  
Author(s):  
Qiyi Chu ◽  
Yong Li ◽  
Jun Xiao ◽  
Dajun Huan ◽  
Xiangyang Zhang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Impact Toughness ◽  
Ultrasonic Vibration ◽  
High Efficiency ◽  
Thermoplastic Composites ◽  
Hot Press ◽  
Scanning Calorimetry ◽  
Fiber Placement ◽  
Automated Fiber Placement ◽  
The Impact

To obtain the autoclave-level mechanical properties using in situ consolidation of thermoplastic composites by automated fiber placement (AFP) with high efficiency is the focus of recent research. Different heat resources were utilized to pursue improved mechanical properties and deposition rates but yet not very satisfactory. In this article, E-glass fiber/polypropylene laminates, manufactured by ultrasonic vibration–assisted AFP (UAFP) and autoclave, were compared by means of mechanical properties and crystallization. The interfacial bonding mechanism was analyzed theoretically based on the principle of ultrasonic heating and the autohesion. The orthogonal tests were designed to study the effect of the process parameters on the interlaminar shear strength (ILSS), including the ultrasonic amplitude, layup speed, and pressure, to optimize the manufacturing process of specimens. The mechanical tests and differential scanning calorimetry (DSC) were utilized to evaluate the ILSS, mode I interlaminar fracture toughness GIC, impact toughness, and degree of crystalline of laminates from hot-press and UAFP. The experimental results indicate that the ILSS of the specimens from UAFP can match with the hot-press specimens. The GIC and the impact toughness of the UAFP specimens are 59.9% and 20.1% lower than the hot-press ones, respectively, which are due to the lower degree of crystalline caused by the higher cooling rate during the UAFP process. The results of DSC show that the crystallinity of specimens made from UAFP is only 38.5%, whereas the 49.2% crystallinity is tested for the hot-press.

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