scholarly journals In Situ Consolidation of Thermoplastic Prepreg by Generating Harmonic Oscillations on the Consolidation Roller

2021 ◽  
Vol 6 (1) ◽  
pp. 1
Author(s):  
Mohammad Bahar ◽  
Marco Brysch ◽  
Michael Sinapius
Keyword(s):  
Contact Time ◽  
Compressive Force ◽  
Harmonic Oscillations ◽  
Fiber Placement ◽  
Specific Strength ◽  
Reinforced Plastics ◽  
Short Contact Time ◽  
Current State ◽  
Automated Fiber Placement ◽  
Strength And Stiffness

Automation technologies such as Automated Fiber Placement (AFP) or Automated Tape Laying (ATL) are widely used in the aerospace industry today. However, these processes can still be further improved for higher productivity. Fiber-reinforced plastics allow the production of components with extremely high specific strength and stiffness. Regarding the automated manufacturing processes, the thermoplastic tape placement offers efficiency improvements compared to the nowadays more commonly used thermoset tape placement, especially through the substitution of the expensive and time-consuming autoclave process. The consolidation of thermoplastic Prepregs is achieved with an elastic or rigid roller according to the current state of the art. The Prepregs must be consolidated precisely on the substrate or on top of each other. The most important process parameters for high-quality laminate structure with low porosity are the control of heat source, consolidation force, consolidation roll speed, and tape tension. The efficiency of the AFP process can generally be improved by increasing the speed of the consolidation roller. By increasing the speed of the consolidation roller, porosity is increased and mechanical properties of the laminate are reduced significantly due to the short contact time between consolidation roller and Prepregs. This study investigates a process that can reduce these challenges by increasing the contact time and force duration of the consolidation roller on the Prepregs. The consolidation roller in this study is additionally to be driven by the harmonic oscillations. The new method allows the consolidation roller to oscillate forward and backward during the fiber placement process. This creates another force vector in addition to the compressive force of the consolidation roller and increases the bonding strength between the layers.

Intrinsic Hybrid Composites for Lightweight Structures: New Process Chain Approaches

2016 ◽  
Vol 1140 ◽  
pp. 239-246 ◽  
Author(s):  
Simon Frederik Koch ◽  
Daniel Barfuss ◽  
Mathias Bobbert ◽  
Lukas Groß ◽  
Raik Grützner ◽  
...  
Keyword(s):  
Hybrid Composites ◽  
Process Chain ◽  
Lightweight Structures ◽  
Fiber Placement ◽  
Reinforced Plastics ◽  
Steel Sheets ◽  
Process Chains ◽  
New Process ◽  
Hybrid Laminates ◽  
Automated Fiber Placement

This publication describes new process chain approaches for the manufacturing of intrinsic hybrid composites for lightweight structures. The introduced process chains show a variety of different part and sample types, like insert technology for fastening of hollow hybrid shafts and profiles. Another field of research are hybrid laminates with different layers of carbon fiber reinforced plastics stacked with aluminum or steel sheets. The derived process chains base on automated fiber placement, resin transfer molding, deep drawing, rotational molding and integral tube blow molding.

An Experimental Study on the Axial Collapse Characteristics of Hybrid Side Member

2006 ◽  
Vol 324-325 ◽  
pp. 411-414
Author(s):  
Kil Sung Lee ◽  
Kwang Hee Im ◽  
In Young Yang
Keyword(s):  
Energy Absorption ◽  
Collapse Mechanism ◽  
Side Member ◽  
Specific Strength ◽  
Reinforced Plastics ◽  
Collapse Characteristics ◽  
Collapse Mode ◽  
Fiber Reinforced Plastics ◽  
Strength And Stiffness ◽  
Shaped Section

The purpose of this study was to develop lightweight hat shaped section side members which absorb the most of the energy during the front-end collision of vehicle. The hybrid side member was manufactured by combination of aluminum and CFRP. An aluminum or CFRP (Carbon Fiber Reinforced Plastics) member is representative lightweight materials but its axial collapse mechanism is different from each other. The aluminum member absorbs energy by stable plastic deformation, while the CFRP member absorbs energy by unstable brittle failure with higher specific strength and stiffness than those in the aluminum member. Based on the respective collapse characteristics of CFRP side and aluminum members, the hybrid side members were tested on the axial collapse loads to get a synergy effect when the member is combined with the advantages of each members, such as energy absorption by the stable folding deformation of the aluminum member and by the high specific strength and stiffness of the CFRP member. Energy absorption capability and collapse mode of the hybrid side members were analyzed.

The Impact Collapse Characteristics of Al/CFRP Members for Light-Weight

2006 ◽  
Vol 321-323 ◽  
pp. 881-884
Author(s):  
In Young Yang ◽  
Kil Sung Lee ◽  
Cheon Seok Cha
Keyword(s):  
Energy Absorption ◽  
Fiber Orientation ◽  
Brittle Failure ◽  
Orientation Angle ◽  
Specific Strength ◽  
Reinforced Plastics ◽  
Collapse Characteristics ◽  
Fiber Orientation Angle ◽  
Strength And Stiffness ◽  
The Impact

In this study, the impact collapse tests were performed to investigate collapse characteristics of Al/CFRP member which were composed of aluminum members wrapped with CFRP (Carbon Fiber Reinforced Plastics) outside aluminum member. Aluminum members absorb energy by stable plastic deformation, while CFRP members absorb energy by unstable brittle failure with higher specific strength and stiffness than those in the aluminum member. In an attempt to achieve a synergy effect by combing the two members, Al/CFRP members were manufactured and impact collapse tests were performed for the members. Based on the respective collapse characteristics of aluminum and CFRP members, the collapse modes and energy absorption capability were analyzed for Al/CFRP member which have different fiber orientation angle of CFRP. Test results showed that the collapse of the Al/CFRP member complemented unstable brittle failure of the CFRP member due to ductile nature of the inner aluminum member and the fiber orientation angle of Al/CFRP members influence energy absorption capability and collapse mode.

scholarly journals A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

2018 ◽  
Vol 2 (3) ◽  
pp. 42 ◽  
Author(s):  
Mohammad Rakhshbahar ◽  
Michael Sinapius
Keyword(s):  
Mechanical Properties ◽  
Composite Structures ◽  
Fiber Composite ◽  
Gap Effect ◽  
Fiber Placement ◽  
Reinforced Plastics ◽  
Novel Approach ◽  
Automated Fiber Placement ◽  
Automated Processing ◽  
Processing Techniques

Automated processing techniques such as automated fiber placement (AFP) or automated tape laying (ATL) are well known nowadays. However, there is still a lot of potential for these methods to achieve better results, especially for large and complex composite structures. In this experimental work, the gap effect with the Automated Fiber Placement is shown and a solution to overcome this drawback is presented. The gaps are particularly apparent on complex and/or double-curved surfaces and reduce the mechanical properties of the composite structure. In order to cover the unavoidable weak area of this effect, a plurality of fiber composite layers are laid on top of one another in order to increase the mechanical properties of components. This in turn makes the components heavier and more expensive to produce. In this new method, the gaps are detected by profile sensor after placement of the tape on the mold. The gaps are filled with the aid of a 3D printer with carbon continuous-fiber reinforced plastics. By combining the 3D printing and AFP technology, composite parts can be manufactured in a more homogeneous manner. Subsequently, the components are produced faster, cheaper and even lighter because of the avoidance of the additional layers.

Effect of Laminate Configurations on Impact Properties of GFRP Composite in Seawater

2007 ◽  
Vol 7-8 ◽  
pp. 223-227
Author(s):  
S.K. Srivastava ◽  
I.P. Singh
Keyword(s):  
Impact Properties ◽  
Specific Strength ◽  
Reinforced Plastics ◽  
Marine Structure ◽  
Hybrid Laminates ◽  
Glass Fibre Reinforced ◽  
Important Field ◽  
Strength And Stiffness ◽  
Transfer Moulding ◽  
The Impact

Hybrid laminates of glass fibre reinforced plastics (GFRP) are being increasingly used for marine structures under multidirectional loadings, due to their anisotropic behavior, corrosion resistance, high specific strength and stiffness. Therefore appropriate laminate configuration for marine environment applications is an important field of study. Five types of fibre epoxy laminates configurations, resulting from different combinations of three layers of chopped strand mats (CSM) and woven roving (WR) were fabricated using the vacuum resin transfer moulding (VRTM) technique. These were investigated for the effect of seawater on its impact properties. The results showed a significant reduction in the impact strength in all types of wet specimens. This behavior may be attributed to penetration of water molecules in the composites. The impact properties of hybrid laminates using a mixture of CSM and WR were found to be better than combination of laminates comprising only CSM and WR under both dry and wet conditions for marine structure.

scholarly journals Design for Composites: Derivation of Manufacturable Geometries for Unidirectional Tape Laying

2019 ◽  
Vol 1 (1) ◽  
pp. 2687-2696
Author(s):  
Harald Voelkl ◽  
Andreas Kießkalt ◽  
Sandro Wartzack
Keyword(s):  
Strength Properties ◽  
Efficient Production ◽  
Specific Energy Absorption ◽  
Fiber Placement ◽  
Reinforced Plastics ◽  
Laminate Design ◽  
Automated Fiber Placement ◽  
Production Techniques ◽  
High Specific Energy ◽  
Design Freedom

AbstractEven though providing excellent specific stiffness and strength properties, high specific energy absorption and a great degree of design freedom, fibre-reinforced plastics still have to make their way into higher volume applications. Addressing the manufacturing challenges, particularly efficient production techniques are Automated Tape Laying (ATL) and Automated Fiber Placement (AFP), as pointed out by various studies and use cases. However, current Computer Aided Engineering approaches for optimised laminate design still lack the capability to produce results suitable for ATL/AFP. A new method for deriving tape courses from any finite element laminate optimisation result is presented and applied to a virtual demonstrator. An outlook is given on further necessities of extending current laminate optimisation approaches.

Automated Fiber Placement of Composite Wind Tunnel Blades: Process Planning and Manufacturing

2019 ◽  
Author(s):  
Ramy Harik ◽  
Joshua Halbritter ◽  
Dawn Jegley ◽  
Ray Grenoble ◽  
Brian Mason
Keyword(s):  
Wind Tunnel ◽  
Process Planning ◽  
Fiber Placement ◽  
Automated Fiber Placement

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.

Non-Premixed Reactive Volatilization Reactor for Catalytic Partial Oxidation of Low Volatility Fuels at a Short Contact Time

2021 ◽  
Author(s):  
Ying Lin ◽  
Xuesong Li ◽  
Martyn Twigg ◽  
William F Northrop
Keyword(s):  
Partial Oxidation ◽  
Contact Time ◽  
Catalytic Partial Oxidation ◽  
Liquid Hydrocarbons ◽  
Short Contact ◽  
Short Contact Time ◽  
Opposed Flow

This work presents a novel non-premixed opposed-flow reactive volatilization reactor that simultaneously vaporizes and partially oxidizes low volatility liquid hydrocarbons at a short contact time (<12 ms). In the reactor,...

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