scholarly journals Rapid pipe moulding process of Carbon Fibre Reinforced Thermoplastics by high-frequency direct resistance heating

2010 ◽  
Author(s):  
K. Tanaka ◽  
R. Harada ◽  
T. Uemura ◽  
T. Katayama ◽  
H. Kuwahara
Keyword(s):  
Carbon Fibre ◽  
High Frequency ◽  
Resistance Heating ◽  
Moulding Process ◽  
Reinforced Thermoplastics

scholarly journals Effect of Carbon Nanotube Deposition Time to the Surface of Carbon Fibres on Flexural Strength of Resistance Welded Carbon Fibre Reinforced Thermoplastics Using Carbon Nanotube Grafted Carbon Fibre as Heating Element

2019 ◽  
Vol 3 (1) ◽  
pp. 9 ◽  
Author(s):  
Kazuto Tanaka ◽  
Takanobu Nishikawa ◽  
Kazuhiro Aoto ◽  
Tsutao Katayama
Keyword(s):  
Shear Strength ◽  
Carbon Nanotube ◽  
Flexural Strength ◽  
Carbon Fibre ◽  
Deposition Time ◽  
Heating Element ◽  
Resistance Heating ◽  
Carbon Fibres ◽  
Lap Shear ◽  
Reinforced Thermoplastics

In recent years, carbon fibre reinforced thermoplastics (CFRTP) are expected to be used as lightweight structural materials for mass-produced vehicles. CFRTP with thermoplastics as matrix allows us to weld them using melting of matrix by heating. We have been developing a direct resistance heating method, which uses carbon fibres as the resistance heating element. Carbon nanotube (CNT) is expected to be used as additive to FRP and we reported that the fibre/matrix interfacial shear strength was improved by grafting CNT on the surface of carbon fibres and tensile lap-shear strength was improved by using CNT grafted carbon fibre as the heating element for welding. For the practical use of CFRTP for structural parts, flexural strength is also necessary to be evaluated. In this study, flexural test was carried out to clarify the effect of CNT deposition time to the surface of carbon fibres on flexural strength of resistance welded CFRTP using CNT grafted carbon fibre as the heating element. The highest flexural strength was obtained when CNT10, for which CNT is grafted on the carbon fibres for deposition time of 10 min, was used for the heating element of resistance welding. In the case of CNT deposition time of 60 min, the lowest flexural strength was obtained because of the poor impregnation of the resin into the carbon fibre due to the excess CNT on the carbon fibres.

scholarly journals DEVELOPMENT OF RAPID PIPE MOULDING PROCESS FOR CARBON FIBER REINFORCED THERMOPLASTICS BY DIRECT RESISTANCE HEATING

2012 ◽  
Vol 06 ◽  
pp. 616-621 ◽  
Author(s):  
KAZUTO TANAKA ◽  
RYUKI HARADA ◽  
TOSHIKI UEMURA ◽  
TSUTAO KATAYAMA ◽  
HIDEYUKI KUWAHARA
Keyword(s):  
Carbon Fiber ◽  
Woven Fabric ◽  
Production Cycle ◽  
Resistance Heating ◽  
Fiber Reinforced ◽  
Heating Method ◽  
Moulding Process ◽  
Carbon Fiber Reinforced ◽  
Reinforced Thermoplastics ◽  
Fiber Reinforced Thermoplastics

To deal with environmental issues, the gasoline mileage of passenger cars can be improved by reduction of the car weight. The use of car components made of Carbon Fiber Reinforced Plastics (CFRP) is increasing because of its superior mechanical properties and relatively low density. Many vehicle structural parts are pipe-shaped, such as suspension arms, torsion beams, door guard bars and impact beams. A reduction of the car weight is expected by using CFRP for these parts. Especially, when considering the recyclability and ease of production, Carbon Fiber Reinforced Thermoplastics are a prime candidate. On the other hand, the moulding process of CFRTP pipes for mass production has not been well established yet. For this pipe moulding process an induction heating method has been investigated already, however, this method requires a complicated coil system. To reduce the production cost, another system without such complicated equipment is to be developed. In this study, the pipe moulding process of CFRTP using direct resistance heating was developed. This heating method heats up the mould by Joule heating using skin effect of high-frequency current. The direct resistance heating method is desirable from a cost perspective, because this method can heat the mould directly without using any coils. Formerly developed Non-woven Stitched Multi-axial Cloth (NSMC) was used as semi-product material. NSMC is very suitable for the lamination process due to the fact that non-crimp stitched carbon fiber of [0°/+45°/90°/-45°] and polyamide 6 non-woven fabric are stitched to one sheet, resulting in a short production cycle time. The use of the pipe moulding process with the direct resistance heating method in combination with the NSMC, has resulted in the successful moulding of a CFRTP pipe of 300 mm in length, 40 mm in diameter and 2 mm in thickness.

scholarly journals Using taguchi approach for investigating mechanical properties of recycled carbon fibre reinforced thermoplastics for injection moulding applications

2021 ◽  
Vol 13 (2) ◽  
pp. 149-154
Author(s):  
Syairah Zainudin ◽  
◽  
Norshah Aizat Shuaib ◽  
Nur’ain Wahidah Ya Omar ◽  
Azwan Iskandar Azmi ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Carbon Fibre ◽  
Injection Moulding ◽  
Orthogonal Design ◽  
High Volume ◽  
Processing Parameters ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Reinforced Thermoplastics ◽  
Taguchi Orthogonal Design

Demand for carbon fibre reinforced plastic (CFRP) increases due to its popular demand in sectors such as automotive and aerospace. This leads to high volume of manufacturing and end of life CFRP waste. The challenge is to recycle the heterogenous waste and utilise the recycled carbon fibre (rCF) in potential applications, including the injection moulding process. However, the effect of processing parameters such as type of new thermoplastics, filler weight loading and particle size on product mechanical properties is not well understood. This study carried out experimental trials based on L4 Taguchi orthogonal design. It is found that the mechanical and physical properties significantly depend on the selected parameters. Optimisation of the parameters should depend on final application of the product. This study highlights potential use of rCF in reinforcing pure thermoplastics, as well as an alternative material to virgin carbon fibre (CF).

scholarly journals Carbon Fiber Reinforced Thermoplastics Molding by Using Direct Resistance Heating to Carbon Nanofilaments Grafted Carbon Fiber

2019 ◽  
Vol 3 (1) ◽  
pp. 14 ◽  
Author(s):  
Kazuto Tanaka ◽  
Ririko Habe ◽  
Masayoshi Tanaka ◽  
Tsutao Katayama
Keyword(s):  
Carbon Fiber ◽  
Void Content ◽  
Resistance Heating ◽  
Fiber Reinforced ◽  
Hot Press ◽  
Molding Method ◽  
Reinforced Thermoplastics ◽  
Reinforcing Fiber ◽  
Fiber Reinforced Thermoplastics ◽  
Press Molding

In the automobile industry, carbon fiber reinforced thermoplastics (CFRTP) have attracted attention as potential materials to reduce the weight of the automobile body. In order to apply CFRTP to mass-produced automobile parts, it is necessary to develop the reduction of molding time and the impregnation method into the carbon fiber (CF) for the thermoplastic resin, which has relatively high viscosity. Although the conventional hot press molding uses only the heat transfer from the mold to the molding materials, it is expected to develop a new molding method for CFRTP using heat generation of the materials themselves to overcome these issues. As a method of heating the carbon fiber, there is a direct resistance heating method, in which carbon fiber is directly energized and heated by Joule heat. We have developed resistance welding methods in which carbon nanotube (CNT) grafted carbon fiber (CNT-CF) is used for the heating elements, and revealed that the higher welded strength is obtained by using CNT-CF instead of CF. Therefore, the carbon nanofilaments (CNF) grafted carbon fiber (CNF-CF) including CNF-CF is expected not only to be used as a resistance heating medium at the time of joining but also as a reinforcing fiber and as a self-heating member at the time of molding. In this study, we develop the CFRTP molding method by using direct resistance heating to CNF-CF in the hot press molding. CFRTP ([0°]20) with the volume fractions (Vf) of 40% are molded by conventional hot press and hot press with direct resistance heating to reinforcing fiber. CF or CNF-CF is used for reinforcement. CFRTP molded by hot press with direct resistance heating to CNF-CF indicated lower void content than CFRTP molded by hot press with direct resistance heating to CF. Compared to CFRTP molding by only hot press, hot press molding with direct resistance heating to CNF-CF can mold CFRTP with low void content.

Torque-Fiber-Winding (TFW)-Procedure: Manufacturing of Textile-Based Unidirectional Prepreg for Raw Material and Material Development of Carbon Fibre Reinforced Thermoplastics

2017 ◽  
Vol 742 ◽  
pp. 498-505
Author(s):  
Angelika Kolonko ◽  
Frank Helbig ◽  
Jürgen Tröltzsch ◽  
Daisy Nestler ◽  
Lothar Kroll
Keyword(s):  
Carbon Fibre ◽  
Degrees Of Freedom ◽  
Single Layer ◽  
Nonwoven Fabric ◽  
Fibre Volume ◽  
Raw Material ◽  
Laboratory Staff ◽  
Material Development ◽  
Fiber Winding ◽  
Reinforced Thermoplastics

There is the need to determine the process capability of available and novel carbon fibre (CF) roving with minimal material and reproducible procedures in the field of research and development of continuous fibre reinforced composites and structural components, as well as to identify the power delivery in thermoplastic laminate constructions. The innovative TFW procedure with the appropriate system technology allows the production of piece size variable unidirectional (UD) prepreg in a continuous sequential process of spiral winding. A flexible surface design, resulting in the partial fixation of a single highly spread CF roving on fine nonwoven fabric. By defined accumulating of composite components, the fibre volume content (FVC) is adjustable and correspond to the level of spreading and to the grammage of nonwoven fabric. Minimum single layer thickness promote compound homogeneity and thereby allow the generation of greatest possible degrees of freedom in load-oriented structural design of CF-reinforced thermoplastic lightweight products in the laboratory staff.

The Design, Development and Manufacture of a New and Unique Tennis Racket

1983 ◽  
Vol 197 (2) ◽  
pp. 71-79 ◽  
Author(s):  
R C Haines ◽  
M E Curtis ◽  
F M Mullaney ◽  
G Ramsden
Keyword(s):  
Carbon Fibre ◽  
Production Efficiency ◽  
Fibre Composite ◽  
Initial Study ◽  
Added Value ◽  
Design Development ◽  
Carbon Fibre Composite ◽  
Moulding Process ◽  
Injection Moulding Process ◽  
Product And Process

This paper describes how a revolutionary new process was devised for producing top quality tennis rackets from carbon fibre reinforced thermoplastic by a specially developed injection moulding process. The product and process were evolved following an initial study by a multi-discipline team in January 1978 which led to a fully engineered manufacturing process starting production in November 1980. The new racket undercuts the price of competitors' carbon fibre composite rackets in a market sector of growing importance, and the ‘added value’ of the product is significantly higher than that for conventional wooden rackets currently manufactured by the Company. When other comparisons are made with wooden racket manufacture, the new product and process show advantages in nearly every aspect of production efficiency. The new racket and process which are protected by three patents, won a Design Council Award in 1981 and was the winner of the Willis Faber Manufacturing Effectiveness Award organized by the Institution of Mechanical Engineers in May 1982.

Specific Mechanical Properties of New Hybrid Laminates with Thermoplastic Matrix and a Variable Metal Component

2015 ◽  
Vol 825-826 ◽  
pp. 344-352 ◽  
Author(s):  
Daisy Nestler ◽  
Heike Jung ◽  
Sebastian Arnold ◽  
Bernhard Wielage ◽  
Guntram Wagner
Keyword(s):  
Mechanical Properties ◽  
Thermal Expansion ◽  
Carbon Fibre ◽  
Aluminium Alloy ◽  
Thermal Expansion Coefficient ◽  
Expansion Coefficient ◽  
Glass Fibre ◽  
Reinforced Plastics ◽  
Hybrid Laminates ◽  
Reinforced Thermoplastics

Hybrid laminates combine the positive properties of metals and fibre reinforced plastics. Thereby, the relatively free selectable components provide further benefits. Especially thermoplastic matrices offer positive aspects like the possibility of deformation, recyclability as well as the possibility of mass production. To obtain such hybrid laminates the first step is the production of pre-consolidated unidirectional endless fibre reinforced thermoplastic foils. In a second step, these pre-impregnated fibre-foil tapes were alternating thermally pressed with metallic layers in tailored compositions. To use the full capacity of the hybrid laminates an adequate interface between the fibre reinforced thermoplastics and the metallic foil is essential. Different investigations of the authors display the principle possibility to produce hybrid laminates with carbon endless fibre reinforced thermoplastics and aluminium alloy foils. Nevertheless, load free delamination’s occurs. The reason for these delaminations within the interface of the fibre reinforced thermoplastics and the metallic foil are the differences in the thermal expansion coefficient of the components. Caused by the consolidation at elevated temperatures these differences become more significant and reduce the reproducibility of the hybrid laminates. To minimize these thermal induced stresses the graduation of the thermal expansion coefficient is one possibility. This graduation is possible by utilising glass fibre thermoplastic tapes between the aluminium alloy foil and the carbon fibre reinforced thermoplastics. Further investigations are dealing with so called expansion alloys to adapt the thermal expansion coefficient. The latter approach provides the benefit to utilize the full mechanical properties of the carbon fibre reinforced thermoplastics and to economize the glass-fibre tapes. Nevertheless, these expansion alloys are characterized by a high density. Hence, within this contribution the specific mechanical properties as well as the advantages and disadvantages of hybrid laminates with expansion alloys or aluminium alloys with glass-fibre thermoplastics interlayers are discussed and assessed. These specific mechanical properties display the potential of the expansion alloy in spite of the high density by means of comparable values. The sample only consisting of carbon fibre reinforced plastics highlights the great variety and possibilities of different hybrid laminate structures and combinations regarding the thickness and positioning of the component layers.

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