Title: Controlling the Geometry of High-Rate Thermoplastic Composites via Over-Braiding

Authors: Jessica Lavorata, Jan-Anders E. Mansson

DOI: 10.33599/nasampe/s.21.0471

Abstract: This paper introduces a novel manufacturing method that produces an intermediate material form known as M-TOW® (multifunctional-tow). M-TOW® integrates different material forms to produce a continuous fiber reinforced rod/tow. The core component, unidirectional pre-impregnated fiber composites, gives the M-TOW® its high-performance mechanical characteristics. The composite tow is lightly over-braided with dry fibers to confine the shape and maintain consolidation during subsequent 3-D forming operations. Finally, a compatibility-promoting polymer coating may be applied to enhance bonding during future additive molding operations. An optimal processing window is developed for full compaction and consolidation to ensure that the M-TOW® retains its high-performance characteristics while being economically viable. This optimal processing window incorporates operating temperature, line speed, braid pressure and braid density. By controlling the over-braid’s tension and speed, the tow achieves near perfect cylindricity with higher fiber volume fraction, thus producing a consolidated composite without using expensive molds. Finally, this work demonstrates the ability to manufacture a high-performance composite which will be used to incorporate additional functional elements.

References: [1] K. Friedrich and A. A. Almajid, “Manufacturing aspects of advanced polymer composites for automotive applications,” Appl. Compos. Mater., vol. 20, no. 2, pp. 107–128, 2013. [2] Eelcee-Ltd., “Over-braided hybrid material manufacturing system,” South Korea Patent 0103194, 2017. [3] K. Minchenkov, A. Vedernikov, and A. Safonov, “Thermoplastic Pultrusion : A Review,” Polymers (Basel)., vol. 13, no. 180, 2021. [4] J. G. Drobny, Industrial Applications of Ionizing Radiation. Elsevier Inc, 2013. [5] L. R. Msalilwa, Y. Kyosev, A. Rawal, and U. Kumar, Recent developments in braiding Cover Factor (%) Oven Temperature (°C) and narrow weaving. Springer, 2016. [6] ASTM E2550-17, “Standard Test Method for Thermal Stability by Thermogravimetry.” ASTM International, West Conshohocken, PA, 2017. [7] T. S. R. Murthy, “A comparison of different algorithms for circularity evaluation,” Precis. Eng., vol. 8, no. 1, pp. 19–23, 1986. [8] P. Potluri, A. Rawal, M. Rivaldi, and I. Porat, “Geometrical modelling and control of a triaxial braiding machine for producing 3D preforms,” Compos. Part A Appl. Sci. Manuf., vol. 34, no. 6 SPEC., pp. 481–492, 2003.

Conference: SAMPE NEXUS 2021

Publication Date: 2021/06/29

SKU: TP21-0000000471

Pages: 12

Price: FREE