Evaluating the potential of forming spot-welded layups out of fibre reinforced thermoplastic tape without previous consolidation
Source abstract
Abstract
With an automated tape laying machine like the Fiberforge RELAY2000, spot-welded 2D layups of unidirectional fibre reinforced thermoplastic tape can be produced within short time. The layup process is usually followed by a consolidation step to remove the air of the layup and to fuse the plies. After this, the preforms can be formed into 3D parts. As the consolidation step is very time and energy consuming, methods were investigated within this study to form carbon fibre reinforced polyamide 6 layups without any previous consolidation. A variety of challenges during pre-heating, handling and forming may occur. To cope with this, a number of different approaches were compared in terms of processability and resulting part quality: 1. Additional ultrasonic spot-welds to improve the heating in an infrared oven. 2. Vacuum setup with polyimide films to remove air and improve the heat transfer between the plies. 3. Vacuum setup with polyamide 6 films with the same aims as with the polyimide foil plus an improved formability. The quality of the formed parts was examined using thermography, microsections, void content and fibre volume fraction measurements. The reference were formed parts made of consolidated preforms. The evaluation revealed that the vacuum setup with polyamide 6 films generated the best results that were also comparable to the reference. The additional matrix material caused a reduction of fibre volume fraction and an increase in thickness, but also enabled new possibilities for joining with other parts.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Additive Manufacturing and 3D Printing Technologies · Manufacturing Process and Optimization · Mechanical Behavior of Composites
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (25)
Show source-provided references
1. Lengsfeld H, Wolff-Fabris F, Krämer J, Lacalle J, Altstädt V (2015) Faserverbundwerkstoffe: Prepregs und ihre Verarbeitung. In: 1st edn. Carl Hanser Verlag, München
2. Dieffenbacher GmbH (2017) Tailored blank line with Fiberforge and Fibercon systems. http://www.dieffenbacher.de/upload/downloads/Brochure_Fiberforge_Fibercon_2017.pdf . Accessed 19 Dec 2017
3. Burkhart A, Cramer D (2006) Continuous-fibre reinforced thermoplastic tailored blanks. JEC Composite Mag 43(22):41–43
4. Campbell F (ed) (2004) Manufacturing processes for advanced composites. Elsevier Science, Amsterdam
5. Åström BT (1997) Manufacturing of polymer composites. CRC Press, London
6. Lebrun G, Denault J, Bureau M (2002) Influence of Consolidation and Forming Parameters in the Molding of Continuous Fibre Reinforced Thermoplastic Composites. In: 2nd Annual Automotive Composites Conference
7. Hohmann A, Albrecht S, Lindner JP et al (2018) Recommendations for resource efficient and environmentally responsible manufacturing of CFRP products. Carbon Composites e.V, Augsburg
8. Almeida O de, Bessard E, Bernhart G (2012) Influence of processing parameters and semi-finished product on consolidation of carbon/PEEK laminates. In: proc. 15th European conference on composite materials ECCM15
9. Radlmaier V, Heckel C, Winnacker M, Erber A, Koerber H (2017) Effects of thermal cycling on polyamides during processing. Thermochim Acta 648:44–51. https://doi.org/10.1016/j.tca.2016.12.01110.1016/j.tca.2016.12.011 ↗
10. Ostgathe M, Breuer U, Mayer C, Neitzel M (1996) Fabric reinforced Thermopalstic composites: manufacturing and processing. In: Proc. 7th European conference on composite materials ECCM7, pp 195–200
11. Wakeman MD, Cain TA, Rudd CD, Brooks R, Long AC (1998) Compression moulding of glass and polypropylene composites for optimised macro- and micro- mechanical properties—1 commingled glass and polypropylene. Compos Sci Technol 58(12):1879–1898. https://doi.org/10.1016/S0266-3538(98)00011-610.1016/S0266-3538(98)00011-6 ↗
12. Trudel-Boucher D, Fisa B, Denault J, Gagnon P (2005) Thermoforming complex parts from unconsolidated and consolidated polypropylene/glass fibre fabrics. Polym Polym Compos 13(6):543–55810.1177/096739110501300601 ↗
13. Trudel-Boucher D, Fisa B, Denault J, Gagnon P (2006) Experimental investigation of stamp forming of unconsolidated commingled E-glass/polypropylene fabrics. Compos Sci Technol 66(3–4):555–570. https://doi.org/10.1016/j.compscitech.2005.05.03610.1016/j.compscitech.2005.05.036 ↗
14. Long AC, Wilks CE, Rudd CD (2001) Experimental characterisation of the consolidation of a commingled glass/polypropylene composite. Compos Sci Technol 61(11):1591–1603. https://doi.org/10.1016/S0266-3538(01)00059-810.1016/S0266-3538(01)00059-8 ↗
15. Svensson N, Shishoo R (1998) Manufactoring of thermoplastic composites from commingled yarns - a review. J Thermoplast Compos Mater 11(1):22–5610.1177/089270579801100102 ↗
16. Slange TK, Warnet L, Grouve W, Akkerman R (2016) Influence of Preconsolidation on consolidation quality after stamp forming of C/PEEK composites. In: Proc. 19th international ESAFORM conference on material forming: ESAFORM201610.1063/1.4963578 ↗
17. AVK–Industrievereinigung Verstärkte Kunststoffe e. V. (2014) Handbuch Faserverbundkunststoffe/Composites: Grundlagen - Verarbeitung - Anwendungen, 4th edn. Springer
18. Celanese (2016) CELSTRAN CFR-TP PA6 CF60–03 - PA6 Datasheet
19. Margossian A (2017) Forming of tailored thermoplastic composite blanks: material characterisation, Simulation and validation. Ph.D. thesis, Technische Universität München
20. Lessard H, Lebrun G, Benkaddour A, Pham XT (2015) Influence of process parameters on the thermostamping of a [0/90]12 carbon/polyether ether ketone laminate. Compos A: Appl Sci Manuf 70:59–68. https://doi.org/10.1016/j.compositesa.2014.12.00910.1016/j.compositesa.2014.12.009 ↗
21. DIN Deutsches Institut für Normung e. V. (1998) DIN EN 2564 - Determination of the fibre-, resin- and void contents
22. Breitenstein O, Warta W, Langenkamp M (2011) Lock-in thermography: basics and applications to functional diagnostics of electronic components. Springer series in advanced microelectronics, vol 10. Springer, Berlin, London
23. Perterer M (2012) Schadenidentifikation und -bewertung von CFK-Bauteilen mittels phasenmodulierter Thermographie. Ph.D. thesis, Technische Universität München
24. Edevis GmbH Testing of CFRP Components. https://www.edevis.com/download/AppNote_OTvis_CFRP_EN.pdf . Accessed 15 Mar 2018
25. Yüksel F, Hinterhoelzl R, Drechsler K (2016) Experimental investigation of direct adhesion of CFR-Thermoplast on steel. In: proc. euro hybrid. Mater Struct 2016