processing of high performance thermoplastic composites · processing of high performance...

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Spring Semester 2017131-5048-00L Manufacturing of Polymer Composites

Joanna Wong 23 March 2017

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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

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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

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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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