Experimental Investigations on Integrated Conductor Paths in Fiber-Reinforced Thermoplastic Composite Structures

2017 ◽  
Vol 742 ◽  
pp. 793-799
Author(s):  
Tony Weber ◽  
Anja Winkler ◽  
Maik Gude
Keyword(s):  
Composite Structures ◽  
Construction Material ◽  
Functional Integration ◽  
Thermoplastic Composite ◽  
Experimental Investigations ◽  
Film Material ◽  
Fiber Reinforced ◽  
Forming Process ◽  
Sensors And Actuators ◽  
Definition Of

By the benefit of functional integration the advantages of fiber reinforced plastics (FRP) as construction material can be increased due to the possibilities of integrating sensors and actuators. In Regard to the layer-by-layer definition of the wall thickness, this class of material offers a high potential for the integration of additional smart elements within the stacking and forming process. In addition to the actual integration methods of sensors or actuators, the electrical signal transmission and contacting is of great importance for smart structures. Various approaches can be followed. On the one hand, the conductor path can be defined by means of a wire and, on the other hand, the definition of conductor paths can be accomplished by functionalized films (by means of printing technology). Within this paper, experimental investigations are intended to demonstrate the suitability of screen-printed conductor paths for the press-technical transformation of FRP structures. In addition to the variation of the screen printing material and the film material, for a material-homogeneous integration, an evaluation of a corresponding selection of materials takes place with respect to the stresses derived from the deformation-technical boundary conditions.

Experimental and Numerical Studies on Integration Thermoplastic Composite Compatible Piezoelectric Ceramics for Actuatory Application of Cylindrical Hollow Structures

2015 ◽  
Vol 825-826 ◽  
pp. 556-562
Author(s):  
Tony Weber ◽  
Maik Gude ◽  
Tobias Kastner
Keyword(s):  
Fiber Composite ◽  
Construction Material ◽  
Experimental Studies ◽  
Thermoplastic Composite ◽  
Fiber Reinforced Composites ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Reinforced Plastics ◽  
Structure Topology ◽  
Definition Of

Regarding the economical use of fiber-reinforced plastics (FRP) as a construction material for structural components whose additional value caused not only in their high specific mechanical properties. Due to the layerwise structure definition of continuous fiber reinforced composites the corresponding production technologies offers a high potential for integration of additional functional elements. Past efforts to the integration of functions in fiber-reinforced composites usual provide in front of a passive use of the piezoelectric effect (eg. structural-health monitoring). Through efficient and structurally defined using of piezoceramic actuators, the planar structure topology of cylindrical hollow FRP profiles can be actively influenced. Based on experimental studies on the definition of basic concepts for the integration of thermoplastic compatible piezoceramic modules (TPM) in fiber composite tubular segments, this paper deals with the understanding and performance capabilities of such actuarical hollow frp structures. The selective excitation and manipulation of the vibration behavior of such rotationally symmetric structures serves for generation of wave effects with radial translational characteristic. The performed experimental studies on the structural behavior of active piezo integral pipe segments are abstracted and compared by means of numerical simulations using multi-physical elements.

Mold technology for mass production of continuous fiber-reinforced sandwich parts

2016 ◽  
Vol 36 (6) ◽  
pp. 589-596 ◽  
Author(s):  
Christian Hopmann ◽  
Philipp N. Wagner ◽  
Robert Bastian ◽  
Kai Fischer ◽  
Arne Böttcher
Keyword(s):  
Systems Engineering ◽  
Composite Structures ◽  
Large Scale ◽  
Functional Integration ◽  
High Surface ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Short Cycle ◽  
Impregnation Process ◽  
Cycle Times

Abstract In order to reduce cycle times, increase functional integration and automation further, the innovative gap impregnation process and mold technology was developed at the Institute of Plastics Processing at RWTH Aachen University (Germany) in collaboration with industry partners. The novel process enables an automated production of continuous fiber-reinforced sandwich composite structures in integral design with high surface quality in short cycle times, which is demonstrated by manufacturing a carbon fiber-reinforced plastic (CFRP) engine hood. For the first time, the gap impregnation and mold technology makes it possible to manufacture large-scale, three-dimensionally shaped sandwich components in one shot and in short cycle times at similar mechanical properties compared to the reference steel hood. Furthermore, a weight reduction of about 60% to only 5 kg was achieved for the CFRP engine hood. This paper focuses on the systems engineering of the RTM-related gap impregnation process. The focus is on the utilized mold concepts for the pressurized air-assisted ejector pins, vacuum-tight sealing, the motion concept of the mold halves, resin traps, sensors for process control and the specially treated mold surfaces for class A surface components. Additionally, the main procedures, capabilities and characteristics of this innovative process are discussed.

Mechanical analysis of thermo-hydroforming of a fiber-reinforced thermoplastic composite helmet using preferred fiber orientation model

2018 ◽  
Vol 52 (23) ◽  
pp. 3183-3198 ◽  
Author(s):  
Hyunchul Ahn ◽  
Nicholas E Kuuttila ◽  
Farhang Pourboghrat
Keyword(s):  
Fiber Orientation ◽  
Mechanical Analysis ◽  
Thermoplastic Composite ◽  
Displacement Curve ◽  
Fiber Reinforced ◽  
Forming Process ◽  
Punch Force ◽  
Explicit Finite Element ◽  
Orientation Model ◽  
Hydroforming Process

The composite thermo-hydroforming process, utilizing heated and pressurized fluid, was used to form an advanced helmet with the Spectra Shield. Experimental results obtained from the forming process show that thermo-hydroforming is a feasible process for manufacturing thermoplastic composite materials. Concurrent to the forming experiments, the forming process was numerically modeled using ABAQUS/CAE. The behavior of the fiber reinforced polymer composite was modeled using the Preferred Fiber Orientation model, which was implemented into the explicit finite element code ABAQUS by writing a User Material Subroutine. The preferred fiber orientation model was further adapted to work with a composite laminate consisting of multiple layers. Numerical results were compared with experimental data to validate the method in terms of predicting the deformed geometry of the multilayer composite, wrinkling, as well as the punch force–displacement curve. Overall, the deformed shape of the fiber-reinforced thermoplastic composite helmet, including the distribution of wrinkles were predicted accurately.

Online Poling of Thermoplastic-Compatible Piezoceramic Modules during the Manufacturing Process of Active Fiber-Reinforced Composites

2015 ◽  
Vol 825-826 ◽  
pp. 787-794 ◽  
Author(s):  
Anja Winkler ◽  
Niels Modler
Keyword(s):  
Manufacturing Process ◽  
Laser Scanning ◽  
Optical Measurement ◽  
High Volume ◽  
Thermoplastic Composites ◽  
Experimental Investigations ◽  
Fiber Reinforced ◽  
Sensors And Actuators ◽  
Component Structure ◽  
Active Fiber

Due to high specific properties and the ability for the realisation of short cycle times within the production process, the use of fiber-reinforced thermoplastic composites offers a high potential for high volume applications. Furthermore, the layered built-up and the according manufacturing processes of these materials give the possibility to integrate functional elements, like electronic components or piezoelectric sensor/actuator modules. Within the collaborative research center CRC/TRR 39 “Production Technologies for light metal and fiber-reinforced composite-based components with integrated piezoceramic Sensors and Actuators”, the integration of piezoceramic modules into lightweight structures ready for series production is investigated. This paper presents the manufacturing process of active fiber-reinforced thermoplastic composites. Here, the focus is on experimental investigations covering the process-integrated poling of novel piezoceramic modules during the manufacturing of active fiber-reinforced thermoplastic components. Therefore, laboratory and process-oriented tests are performed for the determination of appropriate parameters for the pressing and poling process. The functionality of the embedded and poled TPM is validated by the excitation of an active component structure and the optical measurement of the vibration behaviour using a laser scanning vibrometer.

scholarly journals High Performance NbMoTa–Al2O3 Multilayer Composite Structure Manufacturing by Laser Directed Energy Deposition

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1685
Author(s):  
Hang Zhang ◽  
Zihao Chen ◽  
Yaoyao He ◽  
Xin Guo ◽  
Qingyu Li ◽  
...  
Keyword(s):  
Smart Materials ◽  
Composite Structure ◽  
Composite Structures ◽  
High Performance ◽  
Energy Deposition ◽  
Coefficient Of Thermal Expansion ◽  
Multilayer Composite ◽  
Forming Process ◽  
Directed Energy Deposition ◽  
Directed Energy

The conventional method of preparing metal–ceramic composite structures causes delamination and cracking defects due to differences in the composite structures’ properties, such as the coefficient of thermal expansion between metal and ceramic materials. Laser-directed energy deposition (LDED) technology has a unique advantage in that the composition of the materials can be changed during the forming process. This technique can overcome existing problems by forming composite structures. In this study, a multilayer composite structure was prepared using LDED technology, and different materials were deposited with their own appropriate process parameters. A layer of Al2O3 ceramic was deposited first, and then three layers of a NbMoTa multi-principal element alloy (MPEA) were deposited as a single composite structural unit. A specimen of the NbMoTa–Al2O3 multilayer composite structure, composed of multiple composite structural units, was formed on the upper surface of a φ20 mm × 60 mm cylinder. The wear resistance was improved by 55% compared to the NbMoTa. The resistivity was 1.55 × 10−5 Ω × m in the parallel forming direction and 1.29 × 10−7 Ω × m in the vertical forming direction. A new, electrically anisotropic material was successfully obtained, and this study provides experimental methods and data for the preparation of smart materials and new sensors.

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