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.

scholarly journals In Situ Joining of Unidirectional Tapes on Long Fiber Reinforced Thermoplastic Structures by Thermoplastic Automated Fiber Placement for Scientific Sounding Rocket Applications

Procedia CIRP ◽  
2019 ◽  
Vol 85 ◽  
pp. 189-194
Author(s):  
Ralf Engelhardt ◽  
Stefan Ehard ◽  
Tobias Wolf ◽  
Jonathan Oelhafen ◽  
Andreas Kollmannsberger ◽  
...  
Keyword(s):  
Sounding Rocket ◽  
Fiber Reinforced ◽  
Fiber Placement ◽  
Automated Fiber Placement

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.

scholarly journals Influence of Automated Fiber Placement Parameters on Thermoplastic Composite Blanks Used on Stamp Forming Process

2021 ◽  
Author(s):  
Camille Vernejoux ◽  
Xavier Fischer ◽  
Simon Deseur ◽  
Emmanuel Duc
Keyword(s):  
Production Costs ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Manufacturing Processes ◽  
Advanced Manufacturing ◽  
Forming Process ◽  
Fiber Placement ◽  
Automated Fiber Placement ◽  
Stamp Forming ◽  
Manufacturing Time

In recent years, advanced manufacturing processes have been developed to increase the speed of production in order to reduce production costs. At the scale of thermoplastic composites, the translation is the combination of advanced manufacturing processes. The focus in this study is more specifically on the coupling of automated lay-up (AFP) and stamp forming processes. To date, a consolidation process, such as press-consolidation of thermoplastic composites, obtained blanks. Several trials have begun using an automated fiber placement consolidation to reduce manufacturing time and use unidirectional material. However, the combination of AFP and stamp forming is useful if it optimizes this process without the blank’s full consolidation, which by resulting reduces the manufacturing time. This study estimates blank characteristics through thermal history imposed by a more rapid manufacturing process. A set of blanks with varying process parameters is produced to investigate the influence at the microscopic scale. The interface behaviour is observed with optical microscope and image processing. A statistical study applied to the process is carried out in order to relate the material observations to the input parameters. The results of this study are used for the study of the next process of the combination: the stamp forming.

scholarly journals Automated fabrication of hybrid thermoplastic prepreg material to be processed by In-Situ Consolidation Automated Fiber Placement process

2018 ◽  
Vol 188 ◽  
pp. 01024
Author(s):  
Vincenzo Iannone ◽  
Marco Barile ◽  
Leonardo Lecce
Keyword(s):  
Carbon Fiber ◽  
Hot Forming ◽  
Framework Programme ◽  
Thermal Cycles ◽  
Forming Process ◽  
High Performing ◽  
Fiber Placement ◽  
Research And Innovation ◽  
Automated Fiber Placement

This work deals with the fabrication of an innovative hybrid thermoplastic prepreg by continuous hot forming process. The material, suitable also for Automated Fiber Placement process, is produced through a consolidation of commercial PEEK-Carbon Fiber prepreg sandwiched between two amorphous PEI films. Consolidation is performed by a purpose-designed automated prototype equipment operating on defined pressure and thermal cycles. Then preliminary tests on first trials produced were carried out. These activities have been developed in the frame of the NHYTE project, a Research and Innovation Action funded by the European Union's H2020 framework programme, under Grant Agreement No 723309 NOVOTECH acting as Coordinator presents this paper on behalf of all Partners of the project. The proof of NHYTE project concept is the manufacturing of a fastener free and high performing fuselage portion demonstrator.

Effects of processing parameters on the performance of carbon fiber reinforced polyphenylene sulfide laminates manufactured by laser-assisted automated fiber placement

2021 ◽  
pp. 002199832110558
Author(s):  
Dacheng Zhao ◽  
Jiping Chen ◽  
Haoxuan Zhang ◽  
Weiping Liu ◽  
Guangquan Yue ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
Process Parameters ◽  
Compaction Pressure ◽  
Polyphenylene Sulfide ◽  
Void Content ◽  
Fiber Reinforced ◽  
Tool Temperature ◽  
Fiber Placement ◽  
Automated Fiber Placement ◽  
Carbon Fiber Reinforced

In situ consolidation of thermoplastic composites can be realized through laser-assisted automated fiber placement (AFP) technology, and the properties of composites were significant affected by the process parameters. In this work, the effects of process parameters on the properties of continuous carbon fiber–reinforced polyphenylene sulfide (CF/PPS) composites manufactured by laser-assisted AFP were investigated. Four-plies CF/PPS prepreg was laid under the combination of different process parameters and the morphology, void content, crystallinity, and inter-laminar shear strength (ILSS) of the composites were characterized. It turned out that the resin distribution on the surface of the composites could be significantly improved by increasing the laser temperature and compaction pressure. The highest crystallinity of the composites reached 46% at tool temperature of 120°C while the value was only 18% when the tool temperature was 40°C. Meanwhile, with the increasing compaction force ranging of 500–2000 N, the void content of the composites decreased obviously. The ILSS was evaluated through double notch tensile shear test. The results indicated that the mechanical properties of the composites were dominated by void content rather than crystallinity.

scholarly journals Simulation of laser heating distribution for a thermoplastic composite: effects of AFP head parameters

2020 ◽  
Vol 110 (7-8) ◽  
pp. 2105-2117
Author(s):  
Omar Baho ◽  
Gilles Ausias ◽  
Yves Grohens ◽  
Julien Férec
Keyword(s):  
Laser Beam ◽  
Laser Heating ◽  
Thermal Model ◽  
Laser Energy ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Efficient Production ◽  
Fiber Placement ◽  
Aerospace Applications ◽  
Automated Fiber Placement

Abstract Laser-assisted automated fiber placement (AFP) is highly suitable for an efficient production of thermoplastic-matrix composite parts, especially for aeronautic/aerospace applications. Heat input by laser heating provides many advantages such as better temperature controls and uniform heating projections. However, this laser beam distribution can be affected by the AFP head system, mainly at the roller level. In this paper, a new optico-thermal model is established to evaluate the laser energy quantity absorbed by a poly(ether ether ketone) reinforced with carbon fibers (APC-2). During the simulation process, the illuminated radiative material properties are characterized and evaluated in terms of the roller deformation, the tilt of the robot head, and the reflection phenomenon between the substrate and the incoming tape. After computing the radiative source term using a ray-tracing method, these data are used to predict the temperature distribution on both heated surfaces of the composite during the process. The results show that both the roller deformation and the tilt of head make it possible to focus the laser beam on a small area, which considerably affects the quality of the finished part. These findings demonstrate that this optico-thermal model can be used to predict numerically the insufficient heating area and thermoplastic composites heating law.

scholarly journals A comparison of mechanical properties and X-ray tomography analysis of different out-of-autoclave manufactured thermoplastic composites

2020 ◽  
Vol 39 (19-20) ◽  
pp. 703-720
Author(s):  
Diego Saenz-Castillo ◽  
María I Martín ◽  
Vanessa García-Martínez ◽  
Abhiram Ramesh ◽  
Mark Battley ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Raw Material ◽  
Thermoplastic Composites ◽  
Scanning Calorimetry ◽  
Consolidation Process ◽  
Plane Shear ◽  
X Ray ◽  
Void Distribution ◽  
Out Of Autoclave

Three different out-of-autoclave manufacturing processes of CF/poly-ether-ether-ketone thermoplastic composites were characterized, including innovative laser-assisted automated fibre placement with in situ consolidation. Characterization techniques included differential scanning calorimetry, ultrasonic non-destructive testing and matrix digestion, in addition to 3D X-ray microcomputed tomography to investigate the void distribution, size and shape. The results revealed that in situ consolidation process can lead to the accumulation of large voids between the upper layers. Interlaminar shear, in-plane shear, tensile and flexure testing were used for mechanical evaluation. A reduction in the mechanical properties was observed for in situ consolidation laminates when compared to the other out-of-autoclave methods. The drop in mechanical properties of in situ consolidation laminates was mainly attributed to the differences found in void distribution and size. Optimization of processing parameters along with higher quality prepreg raw material could be of assistance for the improvement of mechanical properties of in situ consolidation structures.

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