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| | Spring Semester 2017 131-5048-00L Manufacturing of Polymer Composites Joanna Wong 16 June 2017 15.03.2017 1 Processing of High Performance Thermoplastic Composites
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Spring Semester 2017131-5048-00L Manufacturing of Polymer Composites
Joanna Wong 16 June 2017
15.03.2017 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
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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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Autoclave Processing
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Autoclave vacuum bagging
Zepf H.-P. (Ed.), Faserverbundwerkstoffe mit thermoplastischer Matrix, Expert Verlag, 1997
Release film
Vacuum bag
Bleeder
Vents
Seal
Mould
Laminate
Autoclave table
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Typical autoclave cure cycle
Zepf H.-P. (Ed.), Faserverbundwerkstoffe mit thermoplastischer Matrix, Expert Verlag, 1997
Tem
pera
ture
[°C
]
Pres
sure
[bar
]
Time [hours]
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Processes for Thermoplastic Composites
15.03.2017PROCESSING OF HIGH PERFORMANCE THERMOPLASTIC COMPOSITES 7
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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Continuous belt laminationPalettierung
Abwickelstation Querschneideeinheit
Doppelbandpresse
Besäumstation
Kühlzone
Heizzone
Aufwickelstation
Materialfluss
Palletizing
Cutting unitUnwind station
Double belt press Double beltpress
Heating
Upwind station
Trimming station
Material flow
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Continuous Belt Lamination
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Continuous Belt Lamination
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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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Thermosetting Composite Pultrusion
Video:
https://www.youtube.com/watch?v=sxWtzlitq1A
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Thermoplastic Composite Pultrusion
Kim, Lee, Friedrich “A model for a thermoplastic pultrusion process using commingled yarns” Composite Science and Technology 61, 8, 105-1077 (2001)
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Thermoplastic Composite Pultrusion
Kim, Lee, Friedrich “A model for a thermoplastic pultrusion process using commingled yarns” Composite Science and Technology 61, 8, 105-1077 (2001)
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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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Main steps for the fabrication of thermoplastic composites using thermoforming processes
Mold preparation
Release agent
…
Heating Consolidation Cooling DemouldingPreparation
Melting of thermoplastic material
De-moulding
Trimming
Post-production
Solidification of thermoplastic material
Draping/ forming
Complete fibre-wetting
Compression moulding
Stamp forming
Diaphragma forming
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Preparation of the mould
Release agent
Cutting of the fabric plies
Mould feeding
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Compression moulding
Closing of the mould, cold forming
Starting of the mould program
De-moulding
Trimming
Post-production
Heating Consolidation Cooling DemouldingPreparation
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Process variant: Tubular blowing process
Preparation of the mould
Release agent
Cutting of the fabric plies
Draping of the silicon tube
Mould feeding
Closing of the mould, cold forming
Pressurisation of the silicon tube
Starting of the mould program
De-moulding
Ventilation of silicon tube
Trimming
Post-production
Heating Consolidation Cooling DemouldingPreparation
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Process variant: independent heating and cooling
Transfer of the mould in the hot-press
Closing of the mould, cold forming
Starting of the mould program
Transfer of the mould in the cold-press
Cooling down to de-moulding temperature
Heating Consolidation Cooling DemouldingPreparation
Preparation of the mould
Release agent
Cutting of the fabric plies
Mould feeding
Transfer of the mould in the de-mouldingstation
De-moulding
Trimming
Post-production
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Metallic mould with low thermal mass
Integrated resistance heating
Integrated cooling fluid system
Thermal insulator with integrated resistance heating
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Process variant: QUICKTEMP-process
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Flow Moulding of Glass Mat reinforced Thermoplastics „GMT“
GMT
Fibre length (mm)0 10 25 50
Inte
nsity
Fibre length (mm)0 10 25 50
Inte
nsity
Stamping of Weave reinforced Thermoplastics (eg. Twintex)
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GMTex structure
GMT
Twintex® Fabric
Twintex® Fabric
GMT fills the cavity
Twintex® reinforcement remainsIn the inlay zone
Microscopic view
5 mm
Source: Ronnie Törnqvist (Quadrant Plastic Composites AG), 1st Swiss Sampe Technical Conference, Zurich 2002 15.03.2017PROCESSING OF HIGH PERFORMANCE THERMOPLASTIC COMPOSITES 22
State of the Art in Automotive Industry
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Source: Ronnie Törnqvist (Quadrant Plastic Composites AG), 1st Swiss Sampe Technical Conference, Zurich 2002
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Recent Component Examples
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Overview: Processing routes
ThermoplasticPrepreg
FiberMatrix
Component
Organicsheet
Prepregging
Stamp forming(rubber forming)
FormingSolidification
Contact-freeheating
Contact heatingHeatingImpregnationConsolidation
Double belt lamination
ImpregnationConsolidation
Compressionmoulding:
HeatingConsolidationFormingSolidification
Stamp forming(metalforming)
FormingSolidification
Diaphragma forming
HeatingConsolidationFormingSolidification
Heatedpreform
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Factors influencing the laminate quality
Consolidation time Consolidation pressure
Fiber wettingconsolidation
Polymer degradation
Degree of cristallinityResidual stress
Cooling speed
Heating Consolidation Cooling DemouldingPreparation
Heating time Heating strategy Over-heating
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Preform selection strongly influences processing route and vice versa!
Thermoplastic matrix has to show an adequate thermal stability considering the selected processing route
Viscosity of the polymer matrix should be sufficient to ensure a complete consolidation
Cooling speed is depending on the selected thermoplastic material
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Some general rules…
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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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Preparation of the mould
Release agent
Cutting of the textile or pre-consolidated sheet material
Fixation of the material to the frame
De-moulding
Trimming
Post-production
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Stamp forming
Transfer of the mould in the press
Forming
Cooling
Heating of the preform outside of the moulding device
Heating Consolidation Cooling DemouldingPreparation
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Stamp forming is a non-isothermal moulding process for reinforced or neat plastic sheet-like preforms
If reinforced sheets are subjected to stamp forming, they have usually experienced consolidation prior to moulding.
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Stamp Forming
U. Thomann, Direct Stamp Forming of Non-ConsolidatedCarbon/Thermoplastic Fibre Commingled Yarns, Diss. ETH No. 15302, Zurich, 2003
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Stamp forming process
U. Thomann, Direct Stamp Forming of Non-ConsolidatedCarbon/Thermoplastic Fibre Commingled Yarns, Diss. ETH No. 15302, Zurich, 2003
