Search

DIGITAL LIBRARY: CAMX 2023 | ATLANTA, GA | OCTOBER 30-NOVEMBER 2

Get This Paper

Consolidation of Braided Carbon Fiber/ Thermoplastic Composite Tubes by Induction Welding

Description

Title: Consolidation of Braided Carbon Fiber/ Thermoplastic Composite Tubes by Induction Welding

Authors: Andrew Cromer, Joshua Widawsky, Jaspreet Pandher, Sandi G. Miller, J. Michael Pereira, Brandon Strohminger, Wout De Backer

DOI: 10.33599/nasampe/c.23.0097

Abstract: Thermoplastic composites (TPCs) have experienced renewed enthusiasm within the U.S. aerospace industry, due in part to opportunities for rapidly manufacturing large structures. Unlike the lengthy cure cycles required by thermosets, the thermoplastic matrix prepreg requires only heat and pressure to consolidate consecutive layers of material; with sufficient inter-ply contact time to develop a strong interface. The manufacturing requirements for thermoplastics provide manufacturing flexibility and of particular interest are in-situ consolidation processes, i.e., consolidation during layup on a tool.

In-situ consolidation removes the time-consuming and costly secondary processing step of autoclave or press consolidation. Process variables which contribute to laminate quality include temperature, heat transfer, inter-ply contact time, and consolidation pressure; all of which must be considered when evaluating an in-situ manufacturing method. Most of the work in this area to date has focused on consolidation during automated fiber placement (AFP), where prepreg tows are consolidated when placed on the tool. Considering this process for a braided structure adds complexity relative to AFP due to the rapid lay-down rate of the braider and simultaneous placement of multiple prepreg tows. As such, processes considered for AFP consolidation could not be applied to a braided part.

Alternatively, a fully braided preform could be consolidated on the tool using well established thermoplastic welding / heating techniques. The goal of this effort was to evaluate the effectiveness of induction welding (heating) to consolidate braided carbon fiber/thermoplastic composite tubes up to eight plies in thickness. The manufacturing process, thermal characterization, and initial mechanical property data of the consolidated tubes are reported.

References: 1. Gruber, M.B, et. al. “Thermoplastic in situ placement requires better impregnated tapes and tows”, International SAMPE Technical Conference, 2012. 2. Cai, X., “Determination of Process Parameters for the manufacturing of thermoplastic composite cones using automated fiber placement”, Master’s Thesis, Concordia University, 2012. 3. Grimsley, B.W. et. al. “In-situ consolidation automated fiber placement of thermoplastic composites for high-rate aircraft manufacturing”, SAMPE Technical Conference, 2022 4. Modi, D., Comer, A., O’Higgins, R.M., McCarthy, M.A., “Thermoplastic composites: In-situ consolidation or in-situ Welding?”, ICCM-19 Conference, 2013. 5. C.A. Ageroges and L. Ye, Fusion Bonding of Polymer Composites: From Basic Mechanisms to Process Optimisation. London: Springer-Verlag, 2002. 6. M. Holland, M. J. L. van Tooren, D. Barazanchy, and J. Pandher, “Modeling of induction heating of thermoplastic composites,” J. Thermoplast. Compos. Mater., vol. 35, no. 10, pp. 1772–1789, 2022, doi: 10.1177/0892705720911979. 7. D. Barazanchy, J. Pandher, and M. J. Van Tooren, “The edge-effect in thermoplastic induction welding,” in AIAA Science and Technology Forum and Exposition, AIAA SciTech Forum 2021, 2021, no. January, pp. 1–14. doi: 10.2514/6.2021-1890. 8. A. Yousefpour, M. Hojjati, and J. P. Immarigeon, “Fusion bonding/welding of thermoplastic composites,” J. Thermoplast. Compos. Mater., vol. 17, no. 4, pp. 303–341, 2004, doi: 10.1177/0892705704045187. 9. T. A. Composites, “Toray Cetex ® TC1225 LMPAEK Product Data Sheet,” Morgan Hill, 2023. 10. Haluza, R.T., C. R. Ruggeri, J.M. Pereira, S.G. Miller, C.E. Bakis, K.L. Koudela, K.L. 2022. “Novel Crash Sled with a Translating Support Mass.” Experimental Mechanics, https://doi.org/10.1007/s11340-021-00812-8 11. Pereira, J.M., B. Strohminger, N. Pini, D.M. Revilock, C.R. Ruggeri, S.G. Miller. 2023. “Dynamic Crush Performance of Thermoplastic and Resin Infused Thermoset Triaxially Braided Composite Structures”, Proceedings of the 2023 American Society for Composites Conference, Boston, MA.

Conference: CAMX 2023

Publication Date: 2023/10/30

SKU: TP23-0000000097

Pages: 16

Price: $32.00

Get This Paper