Title: Novel Experimental Unit to Evaluate Inter-Ply and Tool-Ply Friction in Carbon Fiber Reinforced Polymer Composites Prepregs

Authors: Tasnia J. Nur, Zachary T. White, Brendon Bossert, Matthew C. Egloff, Cecily Ryan, Dilpreet Bajwa, Roberta Amendola, Doug Cairns

DOI: 10.33599/nasampe/c.22.0160

Abstract: There exist many challenges in the design and manufacture of complex geometries using carbon fiber reinforced composite prepregs. Frictional phenomena occur between the tool and the heated laminate and between subsequent prepreg plies within a laminate during forming stage of composite parts. The constrains imposed by friction during forming operations may generates major defects, which then transfer into the final component. As a result, characterization of tool/ply and ply/ply friction during composite forming is relevant to achieve process optimization along with high manufacturing quality. Since there is no ASTM standardized procedure available for frictional measurement of composites, most tests are based on different custom built fixtures. A dedicated experimental unit has been designed and constructed at Montana State University for inter-ply and tool-ply frictional characterization of continuous and stretch broken carbon fiber (SBCF) composite prepregs. The unit based on a pull-through test approach, is designed to be fitted in a universal testing machine. The proposed novel testing unit allows for the evaluation of frictional forces by simulating forming process parameters that composite material encounters during forming operation such as temperature, forming rate, normal pressure and ply orientation. Preliminary results from friction experiments using commercial continuous prepreg materials are presented and compared.

References: [1] S. Chand, “Carbon fibers for composites,” J. Mater. Sci., vol. 35, no. 6, pp. 1303–1313, 2000, doi: 10.1023/A:1004780301489. [2] R. Paton, “Forming technology for thermoset composites,” in Composites Forming Technologies: A volume in Woodhead Publishing Series in Textiles, Elsevier Ltd, 2007, pp. 239–255. [3] Y. Ma, T. Centea, S. R. Nutt, G. Nilakantan, and S. Nutt, “Vacuum Bag Only Processing of Complex Shapes: Effect of Corner Angle, Material Properties and Processing Conditions Recyclable Composites for Wind Turbine Blades View project Recycling of Amine/Epoxy Composites View project Title: Vacuum Bag Only Processing of Complex Shapes: Effect of Corner Angle, Material Properties and Processing Conditions,” 2014. Accessed: Apr. 21, 2021. [Online]. Available: https://www.researchgate.net/publication/267333377. [4] T. Centea, L. K. Grunenfelder, and S. R. Nutt, “A review of out-of-autoclave prepregs - Material properties, process phenomena, and manufacturing considerations,” Composites Part A: Applied Science and Manufacturing, vol. 70. Elsevier Ltd, pp. 132–154, Mar. 01, 2015, doi: 10.1016/j.compositesa.2014.09.029. [5] R. K. Pandey and C. T. Sun, “Mechanisms of wrinkle formation during the processing of composite laminates,” Compos. Sci. Technol., vol. 59, no. 3, pp. 405–417, Feb. 1999, doi: 10.1016/S0266-3538(98)00080-3. [6] C. J. Martin, J. C. Seferis, and M. A. Wilhelm, “Frictional resistance of thermoset prepregs and its influence on honeycomb composite processing,” Compos. Part A Appl. Sci. Manuf., vol. 27, no. 10, pp. 943–951, 1996, doi: 10.1016/1359-835X(96)00037-1. [7] H. M. Hsiao, S. M. Lee, and R. A. Buyny, “Core crush problem in manufacturing of composite sandwich structures: Mechanisms and solutions,” AIAA J., vol. 44, no. 4, pp. 901–907, Apr. 2006, doi: 10.2514/1.18067. [8] A. Levy and P. Hubert, “Corner consolidation in vacuum bag only processing of out-of-autoclave composite prepregs laminates Ultrasonic Welding of thermoplastic Composites View project Composite landing gear View project,” 2014. Accessed: Apr. 26, 2021. [Online]. Available: https://www.researchgate.net/publication/263231466. [9] A. R. A. Arafath, R. Vaziri, and A. Poursartip, “Closed-form solution for process-induced stresses and deformation of a composite part cured on a solid tool: Part I - Flat geometries,” Compos. Part A Appl. Sci. Manuf., vol. 39, no. 7, pp. 1106–1117, Jul. 2008, doi: 10.1016/j.compositesa.2008.04.009. [10] N. Ersoy, T. Garstka, K. Potter, M. R. Wisnom, D. Porter, and G. Stringer, “Modelling of the spring-in phenomenon in curved parts made of a thermosetting composite,” Compos. Part A Appl. Sci. Manuf., vol. 41, no. 3, pp. 410–418, Mar. 2010, doi: 10.1016/j.compositesa.2009.11.008. [11] R. P. Mohan, H. Alshahrani, and M. Hojjati, “Investigation of intra-ply shear behavior of out-of-autoclave carbon/epoxy prepreg,” J. Compos. Mater., vol. 50, no. 30, pp. 4251–4268, 2016, doi: 10.1177/0021998316635238. [12] A. C. Long and M. J. Clifford, “Composite forming mechanisms and materials characterisation,” in Composites Forming Technologies: A volume in Woodhead Publishing Series in Textiles, Elsevier Ltd, 2007, pp. 1–21. [13] P. Harrison, R. ten Thije, R. Akkerman, and A. C. Long, “Characterisation and modelling friction at the tool-ply interface for thermoplastic woven composites,” no. January, pp. 1–2, 2010, [Online]. Available: http://www.multi-science.co.uk/wje.htm. [14] S. Chow, “Frictional interaction between blank holder and fabric in stamping of woven thermoplastic composites,” 2002. [15] D. Stefaniak, E. Kappel, T. Spröwitz, and C. Hühne, “Experimental identification of process parameters inducing warpage of autoclave-processed CFRP parts,” Compos. Part A Appl. Sci. Manuf., vol. 43, no. 7, pp. 1081–1091, 2012, doi: 10.1016/j.compositesa.2012.02.013. [16] P. Hallander, M. Akermo, C. Mattei, M. Petersson, and T. Nyman, “An experimental study of mechanisms behind wrinkle development during forming of composite laminates,” Compos. Part A Appl. Sci. Manuf., vol. 50, pp. 54–64, Jul. 2013, doi: 10.1016/j.compositesa.2013.03.013. [17] K. D. Potter, M. Campbell, C. Langer, and M. R. Wisnom, “The generation of geometrical deformations due to tool/part interaction in the manufacture of composite components,” in Composites Part A: Applied Science and Manufacturing, Feb. 2005, vol. 36, no. 2 SPEC. ISS., pp. 301–308, doi: 10.1016/j.compositesa.2004.06.002. [18] T. J. Dodwell, R. Butler, and G. W. Hunt, “Out-of-plane ply wrinkling defects during consolidation over an external radius,” Compos. Sci. Technol., vol. 105, pp. 151–159, Dec. 2014, doi: 10.1016/j.compscitech.2014.10.007. [19] A. M. Murtagh, J. J. Lennon, and P. J. Mallon, “Surface friction effects related to pressforming of continuous fibre thermoplastic composites,” Compos. Manuf., vol. 6, no. 3–4, pp. 169–175, 1995, doi: 10.1016/0956-7143(95)95008-M. [20] S. R. Morris and C. T. Sun, “An investigation of interply slip behaviour in AS4/PEEK at forming temperatures,” Compos. Manuf., vol. 5, no. 4, pp. 217–224, Dec. 1994, doi: 10.1016/0956-7143(94)90136-8. [21] N. Ersoy, K. Potter, M. R. Wisnom, and M. J. Clegg, “An experimental method to study the frictional processes during composites manufacturing,” Compos. Part A Appl. Sci. Manuf., vol. 36, no. 11, pp. 1536–1544, 2005, doi: 10.1016/j.compositesa.2005.02.010. [22] V. Kaushik and J. Raghavan, “Experimental study of tool-part interaction during autoclave processing of thermoset polymer composite structures,” Compos. Part A Appl. Sci. Manuf., vol. 41, no. 9, pp. 1210–1218, 2010, doi: 10.1016/j.compositesa.2010.05.003. [23] R. H. W. ten Thije and R. Akkerman, “Design of an experimental setup to measure tool-ply and ply-ply friction in thermoplastic laminates,” Int. J. Mater. Form., vol. 2, no. SUPPL. 1, pp. 197–200, 2009, doi: 10.1007/s12289-009-0638-y. [24] C. E. Wilks, “Processing techologies for woven glass/polypropylene composites,” University of Nottingham, 1999. [25] A. Rashidi, H. Montazerian, K. Yesilcimen, and A. S. Milani, “Experimental characterization of the inter-ply shear behavior of dry and prepreg woven fabrics: Significance of mixed lubrication mode during thermoset composites processing,” Compos. Part A Appl. Sci. Manuf., vol. 129, no. September 2019, 2020, doi: 10.1016/j.compositesa.2019.105725. [26] C. Pasco, M. Khan, J. Gupta, and K. Kendall, “Experimental investigation on interply friction properties of thermoset prepreg systems,” J. Compos. Mater., vol. 53, no. 2, pp. 227–243, 2019, doi: 10.1177/0021998318781706. [27] B. Hailer, T. A. Weber, S. Neveling, S. Dera, J. C. Arent, and P. Middendorf, “Development of a test device to determine the frictional behavior between honeycomb and prepreg layers under realistic manufacturing conditions,” J. Sandw. Struct. Mater., 2020, doi: 10.1177/1099636220923986. [28] H. S. Grewal and M. Hojjati, “Inter-ply Friction of Unidirectional Tape and Woven Fabric Out-of-autoclave Prepregs,” Int. J. Compos. Mater., vol. 7, no. 6, pp. 161–170, 2017, doi: 10.5923/j.cmaterials.20170706.02.

Conference: CAMX 2022

Publication Date: 2022/10/17

SKU: TP22-0000000160

Pages: 16

Price: $32.00