Tailored irradiation by VCSEL for controlled thermal states in thermoplastic tape placement

Weiler, T.; Striet, Philipp; Voell, Annika; Stollenwerk, Jochen; Janssen, Henning; Emonts, Michael

doi:10.1117/12.2291015

Cited by 9 publications

(16 citation statements)

References 3 publications

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“…On the one hand, the very limited amount of research on thermoset layup does not reflect the current state of the art in industry in terms of power output and layup speed. The development of new heating sources, such as special adaptations of infrared lamps [87], vertical cavity surface emitting lasers (VCSEL) [88] and xenon flash light based technologies [89,90] on the other hand indicates that the need for new solutions exists. A need for further research can therefore be identified in the area of industrial application of infrared heating in thermoset layup.…”

Section: Discussionmentioning

confidence: 99%

A review of radiative heating in automated layup and its modelling

Orth¹

2017

Zeitschrift Kunststofftechnik

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A review of radiative heating in automated layup and its modelling Automated layup processes are highly suitable for an efficient production of carbon fiber reinforced parts, especially for aerospace applications. Heat input by means of radiative heating offers advantages for these processes and is well established in different forms. The presented work reviews the modelling of radiative heating in automated layup, covering thermoset and thermoplastic materials. Laser and infrared heat sources are studied with their characteristics, similarities and differences, as well as optical interaction with the material. Numerical modelling of the heat transfer is presented with an emphasis on implementation of radiative heating. Literaturübersicht zur Strahlungserwärmung in automatisierten Faserablegeverfahren und deren Berechnung Automatisierte Faserablegeverfahren haben sich in der Luft-und Raumfahrt als geeignete Prozesse zur effektiven Produktion etabliert, wobei der Wärmeeintrag durch Strahlung weitrechende Vorteile bietet. Die vorliegende Arbeit fasst Untersuchungen zum Einsatz und insbesondere zur Berechnung von Strahlungsheizungen in spezifischen Anwendungen zusammen und berücksichtigt sowohl thermoplastische als auch duromere Verbundwerkstoffe. Dabei werden die Eigenschaften, Gemeinsamkeiten und Unterschiede von Laser und Infrarot Strahlungsquellen, sowie die optischen Interaktionen mit dem bestrahlten Material betrachtet. Die numerische Abbildung der Wärmeübertragung wird mit einem Fokus auf Strahlungserwärmung beleuchtet.

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Section: Discussionmentioning

confidence: 99%

A review of radiative heating in automated layup and its modelling

Orth¹

2017

Zeitschrift Kunststofftechnik

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“…To achieve the desired processing temperature at the nip line, it is very important to preheat the tape and substrate surfaces because the material is advected or the heat input is transported toward the bonding region with the tape feeding rate. The heat source in ATW processes can be a hot gas torch [5], infrared lamp [6,7], or, recently, nearinfrared (NIR) diode lasers better known as laser-assisted tape winding (LATW) [8][9][10][11][12]. In case of the adjacent hoop winding process which is used to manufacture thermoplastic pipes as seen in Fig.…”

Section: Nomenclature C Pmentioning

confidence: 99%

Non-uniform crystallinity and temperature distribution during adjacent laser-assisted tape winding process of carbon/PA12 pipes

Hosseini

Schäkel

Baran

et al. 2020

Int J Adv Manuf Technol

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The non-uniform temperature and crystallinity distributions present in carbon fiber–reinforced PA12 composite pipes, produced via laser-assisted tape winding (LATW), are investigated in this paper. The width of the laser source is usually larger than the substrate width which causes multiple heating and cooling of some regions of the (neighboring) substrate and hence temperature and crystallinity gradients during the adjacent hoop winding. A kinematic-optical-thermal (KOT) model coupled with a non-isothermal crystallinity model is developed to capture the transient temperature and crystallinity distributions for growing substrate thickness and width. The predicted temperature trends are validated with thermocouple and thermal camera measurements. The substrate temperature varies in the width direction up to 52%. This will lead to extra polymer remelting and possible degradation. The maximum variation of the crystallinity degree across the width is found to be 270% which shows agreement with the trend of the measured crystallinity degree. It is found that a more realistic description of the melting behavior of the matrix is needed to obtain a more accurate prediction of the crystallinity distribution.

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“…At these locations, thermal camera should use different emission coefficient to measure the right temperature. Adapting laser power for the desired temperature at those regions needs such a laser-like VCSEL laser (see Weiler et al 22 ) which could precisely adjust its power toward the gap/overlap regions. Integrating physics-based in-line monitoring model is also another possibility to create such model predictive control model, i.e.…”

Section: Process Improvementmentioning

confidence: 99%

“…Del Castillo et al 17 used fiber-Bragg grating (FBG) sensors and a thermocouple, Stokes-Griffin et al and Scha¨kel et al [18][19][20] used thermocouples and Perez et al 21 used an infrared thermographic camera. In Weiler et al 22 , carbon fiber-reinforced PA12 composites were employed for the LATP process on flat surfaces. Other thermoplastic materials like PEEK CF, PPS CF and PA6 CF were also utilized for placement on flat surfaces as discussed in literature [23][24][25] respectively.…”

Section: Introductionmentioning

confidence: 99%

Temperature variation during continuous laser-assisted adjacent hoop winding of type-IV pressure vessels: An experimental analysis

Zaami

Schäkel

Baran

et al. 2019

Journal of Composite Materials

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Laser-assisted tape winding is an automated process to produce tubular or tube-like continuous fiber-reinforced polymer composites by winding a tape around a mandrel or liner. Placing additional layers on a previously heated substrate and variation in material and process parameters causes a variation in the bonding temperature of fiber-reinforced thermoplastic tapes which need to be understood and described well in order to have a reliable manufacturing process. In order to quantify the variation in this critical bonding temperature, a comprehensive temperature analysis of an adjacent hoop winding process of type-IV pressure vessels is performed. A total of five tanks are manufactured in which three glass/HDPE tapes are placed on an HDPE liner. The tape and substrate temperatures, roller force and tape feeding velocity are measured. The coefficient of variation for each round is characterized for the first time. According to the statistical analysis, the coefficient of variation in substrate temperature is found to be approximately 4.8–8.8% which is larger than the coefficient of variation of the tape temperature which is 2.1–7.8%. The coefficient of variations of the substrate temperatures in the third round decrease as compared with the coefficient of variations in the second round mainly due to the change in gap/overlap behavior of the deposited tapes. Fourier and thermographic analysis evince that the geometrical disturbances such as unroundness and eccentricity have a direct effect on the temperature variation. In addition to the temperature feedback control, a real-time object detection technique with deep learning algorithms can be used to mitigate the unwanted temperature variation and to have a more reliable thermal history.

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Tailored irradiation by VCSEL for controlled thermal states in thermoplastic tape placement

Cited by 9 publications

References 3 publications

A review of radiative heating in automated layup and its modelling

A review of radiative heating in automated layup and its modelling

Non-uniform crystallinity and temperature distribution during adjacent laser-assisted tape winding process of carbon/PA12 pipes

Temperature variation during continuous laser-assisted adjacent hoop winding of type-IV pressure vessels: An experimental analysis

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