Automated fibre placement process for a new hybrid material: A numerical tool for predicting an efficient heating law

Baho, Omar; Ausias, Gilles; Grohens, Yves; Barile, Marco; Lecce, Leonardo; Férec, Julien

doi:10.1016/j.compositesa.2021.106360

Cited by 12 publications

(5 citation statements)

References 24 publications

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“…Using the previously mentioned techniques, it is difficult to directly measure the interaction between the laser beam and the carbon fiber reinforced thermoplastic composite. The optical model for the lay-up process could not be directly validated, but it might be verified indirectly by comparing the simulated and measured temperature distributions [ 16 , 17 , 22 , 34 , 35 ]. Accordingly, the surface temperature experiment was designed with an inclination of the laser beam to investigate the effect of the curvature feature on the surface temperature, microstructure, and melt pool depth and verify the validity of the theoretical model and the optical-thermal simulation model.…”

Section: Methodsmentioning

confidence: 99%

Influence of Curvature Feature on Laser Heating during Tape Placement Process for Carbon Fiber Reinforced Polyether Ether Ketone Composite

Liu

Huan

et al. 2023

Polymers

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The curvature feature makes the irradiance and absorptivity change, resulting in an uneven power density distribution, which affects the quality of composite parts. In this study, a theoretical model-based Super-Gaussian profile beam in the laser irradiation area was established to obtain the heat flux distribution on the curved surface. The effect of curvature on the surface scattering reflection, temperature distribution, and surface morphology were investigated and verified the validity of the theoretical model. Furthermore, the influence of the laser intensity distribution, laser inclination and curvature radius on the power density distribution and distribution uniformity were studied. Research indicated that the power density increases as the distance from the origin increase resulting from the variation of the irradiance and absorptance along the circumference. The flatter the intensity distribution of the laser beam in the height direction, the less uniform the power density distribution. Accordingly, the typical Gaussian profile beam significantly ameliorates the power density distribution. This research provides a novel understanding of using heat sources during laser heating thermoplastic tape placement.

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Section: Methodsmentioning

confidence: 99%

Influence of Curvature Feature on Laser Heating during Tape Placement Process for Carbon Fiber Reinforced Polyether Ether Ketone Composite

Liu

Huan

et al. 2023

Polymers

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“…Literature studies on the processing-property relationships for AFP manufacturing carbon ber (CF)based TPCs have focused on high-performance thermoplastic matrices such as polyetheretherketone (PEEK) [17][18][19][20][21], polyphenyl sul de (PPS) [22][23][24][25], polyetherimide (PEI) [26,27], polytherketone (PEKK) [28,29], or polyethersulfone (PES) [30]. PEEK matrices are more resistant to high temperature and chemical corrosion than other thermoplastic matrices, and as such, the majority of publications have focused almost exclusively on modeling AFP-related processing of CF/PEEK materials such as bonding, void dynamics, crystallization, residual stress development, and degradation.…”

Section: Introductionmentioning

confidence: 99%

The effects of processing parameters on the wedge peel strength of CF/PEEK laminates manufactured using a laser tape placement process

Zhang

Duan

Hong

et al. 2022

Int J Adv Manuf Technol

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Manufacturing thermoplastic composites (TPC) with excellent mechanical properties requires advanced methods with reduced costs and better overall e ciencies. In this study, ber-reinforced thermoplastic polymer composite laminates were manufactured using an automated ber placement (AFP) manufacturing technology. The effects of processing temperature (from 320 ℃ to 500 ℃), lay-up speed (from 20 mm/s to 260 mm/s), consolidation force (from 100 N to 600 N), and prepreg tape tension (from 0 N to 9 N) on the quality of the resulting laminates manufactured using the laser AFP system were investigated. The interlayer bond strength was characterized using wedge peel tests on samples prepared with different process parameters. The studies were complemented by measurements of the thermal properties of the composites using different scanning calorimetry. The optimized process parameter windows were determined to be 360 ℃ to 400 ℃ for the irradiation temperature, 140 mm/s to 160 mm/s for the lay-up speed, 100 N for the consolidation force, and 3 N to 5 N for the prepreg tape tension, respectively. The microscopic analysis of the cross-sections and peel-damaged surfaces revealed that the different distributions of the resin matrix resulting from the different processing parameters affected the interlayer strength. These results may provide an important reference for manufacturing TPC used in aerospace, defense, and automotive applications.

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“…Since the thermoplastic matrix transmits a large portion of the NIR laser radiation (wavelength ≈ 980 nm) [ 16 ], the heating of the tapes occurs via heating of the absorbing carbon fibers and subsequent heat conduction into the surrounding matrix [ 16 , 17 ]. Accordingly, there is no surface heat input, but a volumetric one depending on the fiber matrix distribution, the surface properties and the angle of incident [ 16 , 17 , 18 , 19 ]. The prepregs and the foam substrate differ greatly in these properties, especially due to the absence of carbon fibers in the foam structure.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Use of a PEI Foam as Core Material for the In-Situ Production of Thermoplastic Sandwich Structures Using Laser-Based Thermoplastic Automated Fiber Placement

et al. 2022

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Laser-based thermoplastic automated fiber placement (TAFP) is nowadays mainly used to produce pure carbon fiber-reinforced plastic (CFRP) structures. This paper investigates the feasibility of a novel application: The deposition of thermoplastic prepreg tapes onto a thermoplastic foam for the production of thermoplastic sandwich structures. Therefore, simple deposition experiments of thermoplastic PEEK/CF prepreg tapes on a PEI closed-cell foam were carried out. 3D surface profile measurements and peel tests according to DIN EN 28510-1 standard were used to investigate the joining area and bonding quality. The results show that a cohesive bond is formed between the deposited tapes and the foam core, however the foam structure in the area of the deposited tapes deforms in dependence of the process parameters, and increasingly with higher deposition temperatures. Due to the deformations that occur during tape deposition, the thermomechanical foam behavior under the TAFP process conditions was investigated in more detail in a subsequent study for an extensive parameter space using a simple experimental setup. Results show that for suitable process parameters, namely a short contact time and a high temperature, the foam deformation can be minimized with the simultaneous formation of a thin melting layer required for cohesive bonding. The inner foam core structure remains unaffected.

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Automated fibre placement process for a new hybrid material: A numerical tool for predicting an efficient heating law

Cited by 12 publications

References 24 publications

Influence of Curvature Feature on Laser Heating during Tape Placement Process for Carbon Fiber Reinforced Polyether Ether Ketone Composite

Influence of Curvature Feature on Laser Heating during Tape Placement Process for Carbon Fiber Reinforced Polyether Ether Ketone Composite

The effects of processing parameters on the wedge peel strength of CF/PEEK laminates manufactured using a laser tape placement process

Experimental Investigation on the Use of a PEI Foam as Core Material for the In-Situ Production of Thermoplastic Sandwich Structures Using Laser-Based Thermoplastic Automated Fiber Placement

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