Title: Unique Polyaryletherketone (PAEK) Prepreg Allows High Versatility in Composite Parts Manufacturing using Automated Lay-up

Authors: Justin Merotte, Gilles Larroque, Stuart Green, Didier Padey, Victorien Merle, Denis Cartié and Alexandre Hamlyn

DOI: 10.33599/nasampe/c.19.0825

Abstract: Out of autoclave composite consolidation processes have been of significant interest to the aircraft manufacturing industry for the past few years, where the demand is for very low porosity, high-quality manufactured parts produced at high speed and a minimal cost. This paper presents the latest advances obtained by combining Coriolis Composites Technologies automated fiber placement (AFP) with an innovative low melt polyaryletherketone unidirectional thermoplastic composite tape manufactured by Victrex (VICTREX AE™ 250 UDT). In this work a state-of-the-art laser assisted AFP head was used to produce in-situ and oven consolidated laminated panels. Porosity content, degree of crystallinity and interlaminar shear strength were measured for each consolidation method and the results are presented here. Manufacturing settings were explored, leading to very low porosity content, an acceptable degree of crystallinity and good interlaminar shear strength. The combination of Coriolis AFP and Victrex material showed significant improvements in terms of manufacturing performances.

References: [1] G. Gardiner, « SAMPE Europe highlights: Composites face challenges in next commercial airframes ». [En ligne]. Disponible sur: https://www.compositesworld.com/blog/post/sampe-europe-highlights-composites-face-challenges-in-next-commercial-airframes. [Consulté le: 13-nov-2018]. [2] A. P. da Costa et al., « A Review of Welding Technologies for Thermoplastic Composites in Aerospace Applications », J. Aerosp. Technol. Manag., vol. 4, no 3, p. 255‑265, sept. 2012. [3] J. Sloan, « Daher announces new thermoplastic composite wing rib ». [En ligne]. Disponible sur: https://www.compositesworld.com/news/daher-announces-new-thermoplastic-composite-wing-rib. [Consulté le: 13-nov-2018]. [4] Staff, « Thermoplastic composites gain leading edge on the A380 ». [En ligne]. Disponible sur: https://www.compositesworld.com/articles/thermoplastic-composites-gain-leading-edge-on-the-a380. [Consulté le: 13-nov-2018]. [5] J.-A. E. Manson et J. C. Seferis, « Autoclave Processing of PEEK/Carbon Fiber Composites », J. Thermoplast. Compos. Mater., vol. 2, no 1, p. 34‑49, janv. 1989. [6] T. Kok, « On the consolidation quality in laser assisted fiber placement: The role of the heating phase », sept. 2018. [7] M. Di Francesco, L. Veldenz, G. Dell’Anno, et K. Potter, « Heater power control for multi-material, variable speed Automated Fibre Placement », Compos. Part Appl. Sci. Manuf., vol. 101, p. 408‑421, oct. 2017. [8] A. J. Comer et al., « Mechanical characterisation of carbon fibre–PEEK manufactured by laser-assisted automated-tape-placement and autoclave », Compos. Part Appl. Sci. Manuf., vol. 69, p. 10‑20, févr. 2015. [9] C. M. Stokes-Griffin et P. Compston, « A combined optical-thermal model for near-infrared laser heating of thermoplastic composites in an automated tape placement process », Compos. Part Appl. Sci. Manuf., vol. 75, p. 104‑115, août 2015. [10] G. Dolo, J. Férec, D. Cartié, Y. Grohens, et G. Ausias, « Model for thermal degradation of carbon fiber filled poly(ether ether ketone) », Polym. Degrad. Stab., vol. 143, p. 20‑25, sept. 2017. [11] T. Kok, W. J. B. Grouve, L. Warnet, et R. Akkerman, « Intimate contact development in laser assisted fiber placement », in ECCM17 - 17th European conference on Composite Materials, 2016. [12] T. K. Slange, L. L. Warnet, W. J. B. Grouve, et R. Akkerman, « Deconsolidation of C/PEEK blanks: on the role of prepreg, blank manufacturing method and conditioning », Compos. Part Appl. Sci. Manuf., vol. 113, p. 189‑199, oct. 2018. [13] R. Pitchumani, S. Ranganathan, R. C. Don, J. W. Gillespie, et M. A. Lamontia, « Analysis of transport phenomena governing interfacial bonding and void dynamics during thermoplastic tow-placement », Int. J. Heat Mass Transf., vol. 39, no 9, p. 1883‑1897, juin 1996. [14] J. Tierney et J. W. Gillespie, « Modeling of In Situ Strength Development for the Thermoplastic Composite Tow Placement Process », J. Compos. Mater., vol. 40, no 16, p. 1487‑1506, août 2006. [15] J.-F. Lamèthe, « Etude de l’adhésion de composites thermoplastiques semi-cristallins; Application à la mise en oeuvre par soudure », Paris VI, Paris, 2004. [16] C. M. Stokes-Griffin et P. Compston, « Investigation of sub-melt temperature bonding of carbon-fibre/PEEK in an automated laser tape placement process », Compos. Part Appl. Sci. Manuf., vol. 84, p. 17‑25, mai 2016. [17] Y. M. Boiko, G. Guérin, V. A. Marikhin, et R. E. Prud’homme, « Healing of interfaces of amorphous and semi-crystalline poly(ethylene terephthalate) in the vicinity of the glass transition temperature », Polymer, vol. 42, no 21, p. 8695‑8702, oct. 2001. [18] D. J. Blundell et B. N. Osborn, « The morphology of poly(aryl-ether-ether-ketone) », Polymer, vol. 24, no 8, p. 953‑958, août 1983. [19] A. A. Mehmet-Alkan et J. N. Hay, « The crystallinity of PEEK composites », Polymer, vol. 34, no 16, p. 3529‑3531, janv. 1993. [20] A. A. Mehmet-Alkan et J. N. Hay, « The crystallinity of poly(ether ether ketone) », Polymer, vol. 33, no 16, p. 3527‑3530, janv. 1992. [21] T. W. Giants, « Crystallinity and dielectric properties of PEEK, poly(ether ether ketone) », IEEE Trans. Dielectr. Electr. Insul., vol. 1, no 6, p. 991‑999, déc. 1994. [22] G. Dolo, « Étude expérimentale et modélisation du procédé de placement de fibres avec chauffe laser », thesis, Lorient, 2017. [23] W. J. B. Grouve, Weld strength of laser-assisted tape-placed thermoplastic composites. Enschede: University of Twente [Host, 2012.

Conference: CAMX 2019

Publication Date: 2019/09/23

SKU: TP19-0825

Pages: 18

Price: $36.00