A study on the potential of NCF thermoplastic composites for use in aeronautic structural applications

2011 ◽  
Vol 31 (2-3) ◽  
Author(s):  
Spiros Pantelakis ◽  
Christos Katsiropoulos ◽  
Bernd Meyer
Keyword(s):  
Thermoplastic Composite ◽  
Hot Forming ◽  
Thermoplastic Composites ◽  
Thermoplastic Resin ◽  
Structural Applications ◽  
Complete Series ◽  
Component Manufacturing ◽  
Structural Parts ◽  
Manufacturing Technologies ◽  
Required Quality

Abstract An investigation on the behavior of four new non-crimp fabric (NCF) composite materials developed by using the thermoplastic resin polyetheretherketone (PEEK) was performed with the aim to assess their potential for producing structural airframe parts of the required quality at reduced cost. In this framework, the mechanical behavior as well as the hot forming behavior of the materials developed was experimentally investigated. In addition, the draping behavior of the NCFs was experimentally evaluated to assess their suitability for being exploited in composite component manufacturing technologies involving direct lay-up processes. To better understand the behavior observed, both C-scan ultrasonic and optical microscopy analyses were performed. Furthermore, a complete series of tests was also carried out for the thermoplastic composite APC-2/AS4 to obtain a reference for comparison. The results of the test have shown that the mechanical properties of thermoplastic NCFs compare well with the respective properties of the reference material. Furthermore, the promising results of the hot forming tests support the expectation of using thermoplastic NCF composites in aircraft structural parts. Finally, the improved drapeability of the NCF material allows for a direct lay-up in a curved form tool. In conclusion, the developed thermoplastic NCF composites show a clear potential to compete with the established aeronautical prepreg material APC-2/AS4.

Experimental investigation on a fully thermoplastic composite subjected to repeated impacts

2019 ◽  
Vol 233 (19-20) ◽  
pp. 6985-7002
Author(s):  
S Boria ◽  
A Scattina ◽  
G Belingardi
Keyword(s):  
Composite Laminates ◽  
Mechanical Performance ◽  
Impact Damage ◽  
Energy Levels ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Low Velocity ◽  
Repeated Impacts ◽  
Structural Parts ◽  
The Impact

In the last years, the spread of composite laminates into the engineering sectors was observed; the main reason lies in higher values of strength/weight and stiffness/weight ratios with respect to conventional materials. Firstly, the attention was focused on fibres reinforced with thermosetting matrix. Then, the necessity to move towards low density and recyclable solutions has implied the development of composites made with thermoplastic matrix. Even if the first application of thermoplastic composites can be found into no structural parts, the replacement of metallic structural parts with such material in areas potentially subjected to impact has become worthy of investigation. Depending on the field of application and on the design geometry, in fact, some components can be subjected to repeated impacts at localized sites either during fabrication, activities of routine maintenance or during service conditions. When composite material was adopted, even though the impact damage associated to the single impact event can be slight, the accumulation of the damage over time may seriously weaken the mechanical performance of the structure. In this overview, the capability of energy absorption of a new composite completely made of thermoplastic material was investigated. This material was able to combine two conflicting requirements: the recyclability and the lightweight. In particular, repeated impacts at low velocity, on self-reinforced laminates made of polypropylene (PP), were conducted by experimental drop dart tests. Repeated impacts up to the perforation or up to 40 times were performed. In the analysis, three different energy levels and three different values of the laminate thicknesses were considered in order to analyse the damage behaviour under various experimental configurations. A visual observation of the impacted specimens was done, in order to evaluate the damage progression. Moreover, the trend of the peak force interchanged between specimen and dart and the evolution of both the absorbed energy and of the bending stiffness with the impacts number were studied. The results pointed out that the maximum load and the stiffness of the specimens tended to grow increasing the number of the repeated impacts. Such trend is opposite compared to the previous results obtained by other researchers using thermosetting composites.

Modeling the Adhesion Bonding Mechanism in Overmolding Hybrid Structural Parts for Lightweight Applications

2014 ◽  
Vol 611-612 ◽  
pp. 915-921 ◽  
Author(s):  
Ruggero Giusti ◽  
Giovanni Lucchetta
Keyword(s):  
Experimental Tests ◽  
Thermoplastic Composite ◽  
Side Impact ◽  
Main Process ◽  
Bonding Mechanism ◽  
Forming Process ◽  
Cycle Times ◽  
Significant Case ◽  
Structural Parts ◽  
Manufacturing Technologies

Reducing vehicle weight to decrease energy consumption and engine emissions is one of the major objectives of the automotive industry today. This goal is mainly achieved by developing new manufacturing technologies for structural lightweight components, such as the hybrid injection molding/composite forming process, which involves preforming a thermoplastic composite laminate and overmolding it to add ribs, attachment points and other features. High part lightness, short cycle times and high degree of automation have recently made this technology an effective solution for the manufacturing of automotive interiors, including door side-impact beams and front ends. In this paper a model of the adhesion bonding mechanism between the overmolded reinforced thermoplastic and the formed composite sheet is proposed, and its dependence on the main process parameters is investigated. The model has been developed conducting experimental tests and eventually validated by means of a significant case study.

Quality Controlled UD Tape Production for the Individualised Production of Load Optimised Thermoplastic Composite Parts

2017 ◽  
Vol 742 ◽  
pp. 90-95
Author(s):  
Christian Hopmann ◽  
Christian Beste ◽  
Markus Hildebrandt ◽  
Arne Boettcher ◽  
Kai Fischer
Keyword(s):  
Manufacturing Process ◽  
Individual Component ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Quality Data ◽  
Fibre Distribution ◽  
Weight Content ◽  
Plastics Processing ◽  
Component Manufacturing ◽  
Joining Process

A flexible and individual component manufacturing process for thermoplastic composites (TPC) has been developed at the Institut fuer Kunststoffverarbeitung in Industrie und Handwerk an der RWTH Aachen (Institute of Plastics Processing (IKV) at RWTH Aachen University). The process consists of a quality controlled tape production and a combined forming and joining process with additive manufactured functional structures. This paper describes the requirements for the unidirectional (UD) tape properties and the quality controlled tape production line in order to allow for a flexible and individual component manufacturing of load optimised thermoplastic composite parts. Besides the UD tape geometry and fibre impregnation quality an even fibre distribution over the width of the UD tape is an important characteristic. Results of investigations regarding the online measured quality data (fibre distribution) and offline measured UD tape properties (local fibre weight content) are presented and discussed.

scholarly journals Thermoplastic Composites and Their Promising Applications in Joining and Repair Composites Structures: A Review

Materials ◽  
2020 ◽  
Vol 13 (24) ◽  
pp. 5832
Author(s):  
João Pedro Reis ◽  
Marcelo de Moura ◽  
Sylwester Samborski
Keyword(s):  
Thermoplastic Composite ◽  
Analytical Models ◽  
Thermoplastic Composites ◽  
Structural Elements ◽  
Fusion Bonding ◽  
Composite Systems ◽  
Thermoplastic Matrix ◽  
Structural Applications ◽  
Potential Applications ◽  
Welding Technique

Thermoset fiber reinforced composites, widely used in current structural applications, have complex repair procedures and generates significant amounts of scrap due to its recycling difficulties, which does not comply with the most recent environmental restrictions. These disadvantages may be overcome by using a thermoplastic matrix phase, which is very suitable to be joined and repaired by local melting, making the composite material fully recyclable. This work presents a literature review on the joining methods applicable to thermoplastic based composites and their potential applications to be used as repair procedures in structural elements. The effectiveness of selected adhesive and fusion bonding techniques for several thermoplastic composite systems is evaluated by a comparative study based on the joints’ strength and toughness results available in the literature. This work focuses on the three most promising fusion bonding techniques: Resistance welding, induction welding, and ultrasonic welding. The advantages and drawbacks for each one of these processes are discussed, as well as their suitability for several specific structural applications. In addition, several discordant aspects for each welding technique are identified and the corresponding recommendations are discussed. A compilation of analytical models for the mechanisms of heat generation and transient heat transfer modelling is also presented for each fusion bonding process in order to promote their application in numerical modelling.

Intraply Shearing Characterization of Thermoplastic Composite Materials in Thermoforming Processes

2012 ◽  
Vol 504-506 ◽  
pp. 243-248 ◽  
Author(s):  
Peng Wang ◽  
Nahiene Hamila ◽  
Philippe Boisse
Keyword(s):  
Mechanical Properties ◽  
Composite Materials ◽  
Shear Behavior ◽  
Mechanical Analysis ◽  
Polyphenylene Sulfide ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Thermoplastic Resin ◽  
Plane Shear ◽  
Significant Difference

The Continuous Fibre Reinforcements and Thermoplastic resin (CFRTP) are widely employed in the prepreg processes. Currently, the most used thermoplastic resins in aeronautics are PPS (polyphenylene sulfide) and PEEK (Polyetheretherketone). They present many advantages on their mechanical properties. However, these mechanical properties depend strongly upon the thermoforming conditions, especially the intraply shearing. In order to improve and complete the understanding about the in-plane shear behavior of thermoplastic composite materials in their forming processes, the thermo-mechanical analysis of PPS/carbon and PEEK/carbon commingled fabrics at different forming temperatures are performed by using the bias-extension tests. The experimental data leads to significant difference on the in-plane shear behavior under different temperature, as well as the wrinkles can be noted in certain thermoforming conditions. Therefore, in order to predict the feasible forming conditions and optimize the important forming parameters of the thermoplastic composites, the in-plan shear behaviors in function of temperature will be integrated into our numerical model to carry out the numerical simulations of thermoforming processes.

scholarly journals A Study on the Influence of Hot Press Forming Process Parameters on Flexural Property of Glass/PP Based Thermoplastic Composites Using Box-Behnken Experimental Design

2014 ◽  
Vol 2014 ◽  
pp. 1-6 ◽  
Author(s):  
B. Senthil Kumar ◽  
Subramanian Balachandar
Keyword(s):  
Experimental Design ◽  
Process Parameters ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Woven Composites ◽  
Flexural Property ◽  
Fibre Reinforcement ◽  
Forming Process ◽  
Compression Moulding ◽  
Structural Applications

A thermoplastic composite is produced from polypropylene matrix with glass fibre reinforcement. These types of composite materials are ecofriendly nature due to their reusability after their lifetime. These polymer composites are alternative to heavy metals that are currently being used in many non-structural applications. In spite of being ecofriendly nature, the range of applications is limited due to poor mechanical properties as compared with thermoset matrix composite. Hence an attempt was made in this work to improve the mechanical property such as flexural property of Glass/PP hybrid woven composites by optimizing the parameters during compression moulding, such as mould pressure, mould temperature, and holding time using Box-Behnken experimental design. Each process variables were taken in 3 different levels. Second order polynomial model with quadratic effect was chosen. The optimum combination of process parameters was obtained by using contour diagram. The levels of importance of process parameters on flexural properties were determined by using analysis of variance (ANOVA). The variation of flexural property with cited process parameters was mathematically modelled using the regression analysis.

UNS A97075

Alloy Digest ◽  
1986 ◽  
Vol 35 (7) ◽  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Aluminum Alloy ◽  
High Strength ◽  
Heat Treating ◽  
Good Resistance ◽  
Temperature Performance ◽  
Structural Applications ◽  
Structural Parts ◽  
Very High

Abstract UNS No. A97075 is a wrought precipitation-hardenable aluminum alloy. It has excellent mechanical properties, workability and response to heat treatment and refrigeration. Its typical uses comprise aircraft structural parts and other highly stressed structural applications where very high strength and good resistance to corrosion are required. This datasheet provides information on composition, physical properties, hardness, elasticity, tensile properties, and shear strength as well as fatigue. It also includes information on low temperature performance as well as forming, heat treating, and machining. Filing Code: Al-269. Producer or source: Various aluminum companies.

scholarly journals Adhesion Studies during Generative Hybridization of Textile-Reinforced Thermoplastic Composites via Additive Manufacturing

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3888
Author(s):  
Johanna Maier ◽  
Christian Vogel ◽  
Tobias Lebelt ◽  
Vinzenz Geske ◽  
Thomas Behnisch ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Polyamide 6 ◽  
Thermoplastic Composites ◽  
Efficient Production ◽  
Angle Measurements ◽  
Small Series ◽  
Contact Angle Measurements ◽  
Static Tensile ◽  
Pre Treatment ◽  
Manufacturing Technologies

Generative hybridization enables the efficient production of lightweight structures by combining classic manufacturing processes with additive manufacturing technologies. This type of functionalization process allows components with high geometric complexity and high mechanical properties to be produced efficiently in small series without the need for additional molds. In this study, hybrid specimens were generated by additively depositing PA6 (polyamide 6) via fused layer modeling (FLM) onto continuous woven fiber GF/PA6 (glass fiber/polyamide 6) flat preforms. Specifically, the effects of surface pre-treatment and process-induced surface interactions were investigated using optical microscopy for contact angle measurements as well as laser profilometry and thermal analytics. The bonding characteristic at the interface was evaluated via quasi-static tensile pull-off tests. Results indicate that both the bond strength and corresponding failure type vary with pre-treatment settings and process parameters during generative hybridization. It is shown that both the base substrate temperature and the FLM nozzle distance have a significant influence on the adhesive tensile strength. In particular, it can be seen that surface activation by plasma can significantly improve the specific adhesion in generative hybridization.

Heat Transfer and Crystallization Modeling during Compression Molding of Thermoplastic Composite Parts

2015 ◽  
Vol 651-653 ◽  
pp. 1507-1512 ◽  
Author(s):  
Jalal Faraj ◽  
Baptiste Pignon ◽  
Jean Luc Bailleul ◽  
Nicolas Boyard ◽  
Didier Delaunay ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Physical Properties ◽  
Volume Fraction ◽  
Thermoplastic Composite ◽  
Large Temperature ◽  
Process Conditions ◽  
Thermoplastic Resin ◽  
Whole Process ◽  
Low Viscosity ◽  
Thermo Physical Properties

We present in this paper, the coupling of heat transfer to the crystallization of composite in a closed mold. The composite is based on thermoplastic resin (low viscosity PA 66) with glass fiber (50% volume fraction). In order to realize this coupling, an accurate characterizationof thermo physical properties in process conditions, especially in the molten and solid state is needed. In addition, theidentification of the parameters of crystallization kinetics is required. Therefore, we present the methods that were used to study the thermo physical properties as the thermal conductivity, heat capacity and the specific volume. Moreover, the kinetic of crystallization was estimated over a large temperature range by using Flash DSC and classical DSC. In order to validate the measurements, the whole process was modeled by finite elements. The model includes the resolution of the strong coupling between the heat transfer and crystallization. Finally, the experimental and numerical results were compared.

scholarly journals RICE STRAW/THERMOPLASTIC COMPOSITE: EFFECT OF FILLER LOADING, POLYMER TYPE AND MOISTURE ABSORPTION ON THE PERFORMANCE

CERNE ◽  
2016 ◽  
Vol 22 (4) ◽  
pp. 449-456 ◽  
Author(s):  
Hossein Mohammadi ◽  
Seyedmohammad Mirmehdi ◽  
Lisiane Nunes Hugen
Keyword(s):  
Tensile Strength ◽  
Rice Straw ◽  
Moisture Absorption ◽  
Water Immersion ◽  
Filler Loading ◽  
Thermoplastic Composite ◽  
Modulus Of Rupture ◽  
Thermoplastic Composites ◽  
Composite Effect ◽  
Wet Condition

ABSTRAT Thermoplastic composites made with 45, 60 and 75% of rice straw as filler and two types of thermoplastics, virgin polyethylene (PE) and polypropylene (PP) were evaluated. The final boards were made with and without maleic anhydride modified polypropylene (MAPP) at 2% of the total weight of each specimen. The flexural and tensile strengths were measured for dry composites and also measured after 24 h of water immersion of the composites (wet condition). By increasing the filler content, the flexural and tensile strengths and also the density of the specimens decreased. The type of matrix (PE or PP) did not affect significantly the flexural strength, but PP led to higher values of tensile strength for low fiber loadings (45% and 60%). Coupling agents increased the flexural and tensile strength. After water immersion, modulus of elasticity and modulus of rupture were decreased, while tensile strength was less influenced.

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