Processing of High Performance Thermoplastic Composites · Spring Semester 2017 131-5048-00L...
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Spring Semester 2017131-5048-00L Manufacturing of Polymer Composites
Joanna Wong 23 March 2017
22.03.2017 1
Processing of High Performance Thermoplastic Composites
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Outline
Introduction to Thermoplastic Composites Materials in Thermoplastic Composites Basics of Thermoplastic Composite Processing Intermediate Materials for Thermoplastic Composites Processes for Thermoplastic Composites Joining Techniques Recycling
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Processes for Thermoplastic Composites
Autoclave processing of thermoplastic composites Continuous belt lamination Thermoplastic Composite Pultrusion Thermoforming Stamp Forming Automated Tape laying processing Thermoplastic Composite Filament Winding Additive Manufacturing Thermoplastic LCM
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Automated Tape/Fibre Laying/Placement
Gurit Suprem
ABB Review 2/98; Asea Brown Boveri Ltd., Comm. Zurich, 1998
Robot
Filament windingmachine
Tape laying unit
Component
Material supply
Gurit Supreme
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Automated tape laying process
Prüfkopf
Online-Control
Cooling
HeatedCompactionroll
Pressure
Cooling Consolidation Heating
Insitu-ConsolidationPreform
Well focused
heat source
Pre-heating
Motion direction
Pre-heating
Heating ImpregnationConsolidation Cooling DemoldingPreform
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Sketch of an automated tape winding setup
Y. Toso, Effective Automated Tape Winding Process with On-Line Bonding under Transient Thermal Conditions, Diss. ETH No. 14983, Zurich, 2003
Spool
Tow Guide 1
Nip Point Heating
Pyrometer
MandrelCompaction Roller
Pyrometer
Tow Guide 2
Hot Guns 1
Preheating 1
Preheating 2
Hot Guns 2
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Tape-laying unit (Prototype)
Pitchumani, R.; Gillespie, J.W. Jr.; Lamontia, M.A.: Design and Optimalization of a Thermoplastic Tow-Placement Process with in-situ Consolidation; in Journal of Composite Materials, Vol. 31, No. 3/1997
Tape material delivery
Heat source(Hot gas)
Compaction roll
Cutting device
Pyrometer
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Automated Tape Laying
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Automated Tape Laying
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ATL Laminate quality vs. line speed
Pitchumani, R.; Gillespie., J.W., Jr.; Lamontia, M.A.: Design and Optimalization of a Thermoplastic Tow-Placement Process with in-situ Consolidation,Journal of Composite Materials, Vol. 31, No. 3/1997
T1: Preheater Torch TemperatureT2: Main Heater Torch TemperatureN: Number of LayersDb: Degree of Bonding
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ATL Void content vs line speed
T1: Preheater Torch TemperatureT2: Main Heater Torch TemperatureN: Number of Layers
Pitchumani, R.; Gillespie., J.W., Jr.; Lamontia, M.A.: Design and Optimalization of a Thermoplastic Tow-Placement Process with in-situ Consolidation,Journal of Composite Materials, Vol. 31, No. 3/1997
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Processes for Thermoplastic Composites
Autoclave processing of thermoplastic composites Continuous belt lamination Thermoplastic Composite Pultrusion Thermoforming Stamp Forming Automated Tape laying processing Thermoplastic Composite Filament Winding Additive Manufacturing Thermoplastic LCM
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Filament Winding
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Filament Winding
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Thermoplastic Composite Filament Winding
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Thermoplastic Composite Filament Winding
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Thermoplastic Composite Filament Winding
Javier Molina Blanco, MT (2015)
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Thermoplastic Composite Filament Winding
Javier Molina Blanco, MT (2015)
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Thermoplastic Composite Filament Winding
Javier Molina Blanco, MT (2015)
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Processes for Thermoplastic Composites
Autoclave processing of thermoplastic composites Continuous belt lamination Thermoplastic Composite Pultrusion Thermoforming Stamp Forming Automated Tape laying processing Thermoplastic Composite Filament Winding Additive Manufacturing Thermoplastic LCM
22.03.2017PROCESSING OF HIGH PERFORMANCE THERMOPLASTIC COMPOSITES 20
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Additive Manufacturing
Also known as 3D Printing Manufacturing process that builds structures by adding material as
opposed to subtractive manufacturing techniques like machining Used in polymers, metals, ceramics, food, and more recently for
composites Still many problem with regards to quality and designs to be
overcome
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Additive Manufacturing
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Additive Manufacturing
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Additive Manufacturing
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Martin Eichenhofer (2016)
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Additive Manufacturing
Challenges Limited material selection Quality of printed material Limited use of anisotropic properties
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Processes for Thermoplastic Composites
Autoclave processing of thermoplastic composites Continuous belt lamination Thermoplastic Composite Pultrusion Thermoforming Stamp Forming Automated Tape laying processing Thermoplastic Composite Filament Winding Additive Manufacturing Thermoplastic LCM
22.03.2017PROCESSING OF HIGH PERFORMANCE THERMOPLASTIC COMPOSITES 27
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Thermoplastic LCM
Research stage technology
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New Polymer Chemistry
Reactive Monomerseg. Caprolactam PA6
Low viscosity Thermoplastics
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Thermoplastic RTM
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Start @ 1:30
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Thermoplastic LCM
Challenges Existing polymer chemistries do not yet have ideal properties Condensation reaction out gassing Insufficient mechanical properties
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