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Advanced Manufacturing Technologies of Thermoplastic Composites

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Advanced Composites".

Deadline for manuscript submissions: closed (15 August 2024) | Viewed by 22051

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Dr. Tian Zhao

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Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing, China
Interests: thermoplastic composites; 3D printing; welding techniques; structural design

Special Issue Information

Dear Colleagues,

Thermoplastic composites are increasingly being applied to aerospace and automotive engineering owing to their versatile properties, such as excellent fracture toughness and impact resistance, cycling possibility, infinite shelf life, etc. One of the most attractive properties of thermoplastic composites is that they can be fabricated using out-of-autoclave (OOA) techniques such as thermal forming, welding, 3D printing, etc., which provides them with super cost-effective manufacturing processes. Based on the driving force from the continuous increase of the demand in aircraft and automotive industries combined with the requirement to lower the environmental impacts of aviation emissions, the thermoplastic composite market is expected to show an exponential increase in the coming decades. However, there are still numerous scientific and technical knowledge gaps in their manufacturing processes which suppress the readiness levels and hence limit their current applications. Therefore, this Special Issue aims to gain deeper insights into the physical evolution mechanisms of the advanced manufacturing techniques of thermoplastic composites, thus laying a solid foundation for their further industrial application. We welcome submissions covering but not limited to the following topics which list in the keywords.

Dr. Tian Zhao
Guest Editor

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Keywords

thermoplastic composites
thermoplastic resins
manufacturing techniques
physical mechanisms
processing modeling
mechanical evaluation
functional design

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Published Papers (11 papers)

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Editorial

Jump to: Research

2 pages, 137 KiB

Open AccessEditorial

Advanced Manufacturing Technologies of Thermoplastic Composites

by Tian Zhao

Materials 2024, 17(22), 5564; https://doi.org/10.3390/ma17225564 - 14 Nov 2024

Viewed by 891

Abstract

Thermoplastic composites are becoming increasingly attractive to the aerospace and automotive industries owing to their outstanding mechanical properties and cost-effective manufacturing processes [...] Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

Research

Jump to: Editorial

16 pages, 13683 KiB

Open AccessArticle

The Effects of Laser-Assisted Winding Process Parameters on the Tensile Properties of Carbon Fiber/Polyphenylene Sulfide Composites

by Hongbo Geng, Xuewen Cao, Lei Zu, Helin Pan, Guiming Zhang, Qian Zhang, Jianhui Fu, Lichuan Zhou, Qiaoguo Wu, Xiaolong Jia and Honghao Liu

Materials 2024, 17(18), 4664; https://doi.org/10.3390/ma17184664 - 23 Sep 2024

Cited by 3 | Viewed by 1144

Abstract

Currently, there is limited research on the in situ forming process of thermoplastic prepreg tape winding, and the unclear impact of process parameters on mechanical properties during manufacturing is becoming increasingly prominent. The study aimed to investigate the influence of process parameters on the mechanical properties of thermoplastic composite materials (CFRP) using laser-assisted CF/PPS winding forming technology. The melting point and decomposition temperature of CF/PPS materials were determined using DSC and TGA instruments, and based on the operating parameters of the laser-assisted winding equipment, the process parameter range for this fabrication technology was designed. A numerical model for the temperature of laser-heated CF/PPS prepreg was established, and based on the filament winding process setup, the heating temperature and tensile strength were simulated and tested. The effects of process parameters on the heating temperature of the prepreg and the tensile strength of NOL rings were then analyzed. The non-dominated sorting genetic algorithm (NSGA-II) was employed to globally optimize the process parameters, aiming to maximize winding rate and tensile strength. The results indicated that core mold temperature, winding rate, laser power, and their interactions significantly affected mechanical properties. The optimal settings were 90 °C, 418.6 mm/s, and 525 W, achieving a maximum tensile strength of 2571.51 MPa. This study provides valuable insights into enhancing the forming efficiency of CF/PPS-reinforced high-performance engineering thermoplastic composites. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

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20 pages, 13103 KiB

Open AccessArticle

Response Surface Methodology Optimization of Resistance Welding Process for Unidirectional Carbon Fiber/PPS Composites

by Da-Wei Yu, Xiao-Ting Qing, Hong-Yu Lin, Jie Yang, Jia-Cao Yang and Xiao-Jun Wang

Materials 2024, 17(10), 2176; https://doi.org/10.3390/ma17102176 - 7 May 2024

Cited by 7 | Viewed by 1569

Abstract

The use of thermoplastic composites (TPCs) as one of the lightweight solutions will inevitably encounter problems in connection. Resistance welding has the characteristics of high strength, simplicity, and high reliability, and is considered a very potential hot-melt connection technology. The resistance welding technology of unidirectional carbon fiber-reinforced polyphenylene sulfide composites (UCF/PPS) was systematically studied. The experimental results show that the 100-mesh brass mesh has the best resin wetting effect and heating efficiency, and the PPS/oxidized 100-mesh brass mesh composite resistance element (Ox-RE/PPS) has the highest welding strength. The welding failure mode changes from interface failure and RE failure to interlayer structure damage and fiber fracture. The single-factor experimental results show that the maximum welding strength is reached at 310 °C, 1.15 MPa, and 120 kW/m². According to the conclusion of the single-factor experiment, the Box–Behnken method was further used to design a three-factor, three-level experiment, and a quadratic regression model was established according to the test results. The results of variance analysis, fitting curve analysis, and perturbation plot analysis proved that the model had high fitting and prediction abilities. From the 3D surface diagram analysis, the influence of power density is the largest, and the interaction between welding temperature and power density is the most significant. Combined with the analysis of Design Expert 13 software, the optimal range of process parameters was obtained as follows: welding temperature 313–314 °C, welding pressure 1.04–1.2 MPa, and power density 124–128 kW/m². The average strength of resistance welding joints prepared in the optimal range of process parameters was 13.58 MPa. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

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16 pages, 6505 KiB

Open AccessArticle

Interfacial Enhancement and Composite Manufacturing of Continuous Carbon-Fiber-Reinforced PA6T Composites via PrePA6T Ultrafine Powder

by Jiahong Yao, Zhao Wang, Jiacao Yang, Xiaojun Wang and Jie Yang

Materials 2024, 17(7), 1557; https://doi.org/10.3390/ma17071557 - 28 Mar 2024

Cited by 1 | Viewed by 1440

Abstract

Semi-aromatic poly (hexamethylene terephthalamide) (PA6T) oligomer (prePA6T) ultrafine powder, with a diameter of <5 μm, was prepared as an emulsion sizing agent to improve the impregnation performance of CF/PA6T composites. The prePA6T hyperfine powder was acquired via the dissolution and precipitation “phase conversion” method, and the prePA6T emulsion sizing agent was acquired to continuously coat the CF bundle. The sized CF unidirectional tape was knitted into a fabric using the plain weave method, while the CF/PA6T laminated composites were obtained by laminating the plain weave fabrics with PA6T films. The interfacial shear strength (IFSS), tensile strength (TS), and interlaminar shear strength (ILSS) of prePA6T-modified CF/PA6T composites improved by 54.9%, 125.3%, and 120.9%, respectively. Compared with the commercial polyamide sizing agent product PA845H, the prePA6T sizing agent showed better interfacial properties at elevated temperatures, especially no TS loss at 75 °C. The SEM observations also indicated that the prePA6T emulsion has an excellent impregnation effect on CF, and the fracture mechanism shifted from adhesive failure mode to cohesive failure mode. In summary, a facile, heat-resistant, undamaged-to-fiber environmental coating process is proposed to continuously manufacture high-performance thermoplastic composites, which is quite promising in mass production. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

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14 pages, 3258 KiB

Open AccessArticle

Innovative CF/PVC Foam Applicated for Automotive Synthetic Leather with High-Performance and Reduced VOC Emissions

by Hongfu Li, Ying Wu, Lingyan Wu, Changwei Cui and Kangmin Niu

Materials 2024, 17(5), 1076; https://doi.org/10.3390/ma17051076 - 26 Feb 2024

Cited by 3 | Viewed by 2399

Abstract

Polyvinyl chloride (PVC) foam, valued for its mechanical and thermal properties along with cost-effectiveness, is extensively utilized across diverse industries. However, its high volatile organic compound (VOC) emissions hinder its adoption in eco-friendly synthetic leather. This study proposes a solution by optimizing the formulation design and foaming processes and achieving mechanical property enhancement via carbon-fiber-reinforced PVC composite foam (CF/PVC). The aim is to reduce PVC usage via enhancing its intrinsic properties. Systematic investigations were carried out on the impact of foaming raw materials, foaming processes, fiber content, and fiber length on the foaming performance, mechanical properties, and VOC emissions. The material formulation and process parameters were successfully optimized. Further assessment of various indicators such as the density, mechanical properties, and tear resistance of synthetic leather samples confirmed that the innovative CF/PVC foam developed in this study meets the requirements for automotive interior applications. Notably, the tensile strength and tear resistance of CF/PVC composite synthetic leather increased by 50% and 29%, respectively, compared to pure PVC, while VOC emissions decreased by 28%. It is anticipated that a more pronounced reduction in VOC emissions will be achieved in practical automotive interior leather applications when further considering the reinforcing effect of fibers, which leads to a reduction in PVC usage. The findings present a technical reference for innovative applications, aiming to enhance PVC foam performance and minimize emissions. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

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18 pages, 4932 KiB

Open AccessArticle

The Influence of Thermal Parameters on the Self-Nucleation Behavior of Polyphenylene Sulfide (PPS) during Secondary Thermoforming

by Yi Ren, Zhouyang Li, Xinguo Li, Jiayu Su, Yue Li, Yu Gao, Jianfeng Zhou, Chengchang Ji, Shu Zhu and Muhuo Yu

Materials 2024, 17(4), 890; https://doi.org/10.3390/ma17040890 - 15 Feb 2024

Cited by 2 | Viewed by 1683

Abstract

During the secondary thermoforming of carbon fiber-reinforced polyphenylene sulfide (CF/PPS) composites, a vital material for the aerospace field, varied thermal parameters profoundly influence the crystallization behavior of the PPS matrix. Notably, PPS exhibits a distinctive self-nucleation (SN) behavior during repeated thermal cycles. This behavior not only affects its crystallization but also impacts the processing and mechanical properties of PPS and CF/PPS composites. In this article, the effects of various parameters on the SN and non-isothermal crystallization behavior of PPS during two thermal cycles were systematically investigated by differential scanning calorimetry. It was found that the SN behavior was not affected by the cooling rate in the second thermal cycle. Furthermore, the lamellar annealing resulting from the heating process in both thermal cycles affected the temperature range for forming the special SN domain, because of the refined lamellar structure, and expelled various defects. Finally, this study indicated that to control the strong melt memory effect in the first thermal cycle, both the heating rate and processing melt temperature need to be controlled simultaneously. This work reveals that through collaborative control of these parameters, the crystalline morphology, crystallization temperature and crystallization rate in two thermal cycles are controlled. Furthermore, it presents a new perspective for controlling the crystallization behavior of the thermoplastic composite matrix during the secondary thermoforming process. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

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17 pages, 9160 KiB

Open AccessArticle

Effect of Process Parameters on Joint Performance in Hot Pressure Welding of 6061 Aluminum Alloy to CF/PA66

by Haipeng Zhou, Yang Li, Weidong Liu, Yan Luo, Sansan Ao and Zhen Luo

Materials 2024, 17(2), 329; https://doi.org/10.3390/ma17020329 - 9 Jan 2024

Cited by 3 | Viewed by 1650

Abstract

Polymer–metal hybrid structures combine the merits of polymer and metal materials, making them widely applicable in fields such as aerospace and automotive industries. However, the main challenge lies in achieving efficient and strong connections between the metal and polymer components. This paper uses the jet electrochemical machining (Jet-ECM) method to customize the surface morphologies on 6061 aluminum alloy (AA6061) sheets. The connection between AA6061 and carbon fiber-reinforced PA66 (CF/PA66) is then achieved through hot pressure welding (HPW). The effects of aluminum alloy surface morphology, welding force, and welding time on the mechanical properties and microstructure of the joint are investigated. The optimal process parameters are determined by the design of the experiment. The results show that the aluminum alloy surface morphology has the greatest impact on the mechanical property of the welded joint. The optimal process parameters are surface morphology with wider, shallower, and sparsely distributed grooves on the aluminum alloy surface, the welding force is 720 N, the welding time is 12 s, the welding temperature is 360 °C, the cooling time is 16 s, and the optimal peak load of the joint is 6690 N. Under the optimal parameters, the fracture morphology in the AA6061 side is almost entirely covered with CF/PA66. The joint experiences cohesive failure in most areas and fiber-matrix debonding in a small area. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

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16 pages, 13592 KiB

Open AccessArticle

Evolution of Manufacturing Defects of 3D-Printed Thermoplastic Composites with Processing Parameters: A Micro-CT Analysis

by Hantai Wu, Xinyu Chen, Shuaiheng Xu and Tian Zhao

Materials 2023, 16(19), 6521; https://doi.org/10.3390/ma16196521 - 30 Sep 2023

Cited by 10 | Viewed by 2091

Abstract

Owing to the melting and healing properties of thermoplastic resin, additive manufacturing or 3D printing is considered one of the most promising technologies for fiber-reinforced thermoplastic composites. However, manufacturing defects are still the main concern, which significantly limits the application of 3D-printed composite structures. To gain an insight into the effects of different processing parameters on the typical manufacturing defects, a micro-scale analysis was carried out via Micro-CT technology on the 3D-printed continuous carbon fiber-reinforced polylactic acid (PLA) composite specimens. The bias distribution of the fiber in the deposited filament was found. Moreover, when the feed rate of the filament was reduced from 100% to 50%, the a/b value was closer to 3.33, but the porosity increased from 7.077% to 25.352%. When the layer thickness was 0.2 mm, the increased nozzle pressure reduced the porosity but also increased the risk of fiber bundle breakage. The research provides an effective approach for analyzing the micro-structure of 3D printed composite structures and thus offers guidance for the processing control. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

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16 pages, 5555 KiB

Open AccessEditor’s ChoiceArticle

Automated Fiber Placement Path Planning and Analysis of Pressure Vessels

by Bo Wang, Lihua Wen, Jinyou Xiao, Shiyu Wang, Ping Ren, Liqiang Wang, Lei Zu and Xiao Hou

Materials 2023, 16(18), 6187; https://doi.org/10.3390/ma16186187 - 13 Sep 2023

Cited by 3 | Viewed by 2911

Abstract

The automated fiber placement (AFP) process faces a crucial challenge: the emergence of out-of-plane buckling in thermoplastic prepreg tows during steering, significantly impeding the quality of composite layup. In response, this study introduces a novel approach: the development of equations for wrinkle-free fiber placement within composite pressure vessels. The investigation encompasses a detailed analysis of prepreg trajectories in relation to shell geometry, accompanied by an in-depth understanding of the underlying causes of wrinkling on dome surfaces. Moreover, a comprehensive model for shell coverage, grounded in placement parameters, is meticulously established. To validate the approach, a simulation tool is devised to calculate press roller motions, ensuring the uniform fiber dispersion on the mandrel and achieving flawless coverage of the shell without wrinkles. This innovative strategy not only optimizes the AFP process for composite layup but also remarkably enhances the overall quality of composite shells. As such, this research carries significant implications for the advancement of composite manufacturing techniques and the concurrent improvement in material performance. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

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17 pages, 8827 KiB

Open AccessEditor’s ChoiceArticle

Study on the Overmolding Process of Carbon-Fiber-Reinforced Poly (Aryl Ether Ketone) (PAEK)/Poly (Ether Ether Ketone) (PEEK) Thermoplastic Composites

by Ziyue Zhao, Jindong Zhang, Ran Bi, Chunhai Chen, Jianan Yao and Gang Liu

Materials 2023, 16(12), 4456; https://doi.org/10.3390/ma16124456 - 18 Jun 2023

Cited by 8 | Viewed by 2630

Abstract

This paper used poly (aryl ether ketone) (PAEK) resin with a low melting temperature to prepare laminate via the compression-molding process for continuous-carbon-fiber-reinforced composites (CCF-PAEK). Then, poly (ether ether ketone) (PEEK), or a short-carbon-fiber-reinforced poly (ether ether ketone) (SCF-PEEK) with a high melting temperature, was injected to prepare the overmolding composites. The shear strength of short beams was used to characterize the interface bonding strength of composites. The results showed that the interface properties of the composite were affected by the interface temperature, which was adjusted by mold temperature. PAEK and PEEK formed a better interfacial bonding at higher interface temperatures. The shear strength of the SCF-PEEK/CCF-PAEK short beam was 77 MPa when the mold temperature was 220 °C and 85 MPa when the mold temperature was raised to 260 °C. The melting temperature did not significantly affect the shear strength of SCF-PEEK/CCF-PAEK short beams. For the melting temperature increasing from 380 °C to 420 °C, the shear strength of the SCF-PEEK/CCF-PAEK short beam ranged from 83 MPa to 87 MPa. The microstructure and failure morphology of the composite was observed using an optical microscope. A molecular dynamics model was established to simulate the adhesion of PAEK and PEEK at different mold temperatures. The interfacial bonding energy and diffusion coefficient agreed with the experimental results. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

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13 pages, 6114 KiB

Open AccessCommunication

Parametric Investigation into the Shear Strength of Adhesively Bonded Single-Lap Joints

by Quanlong Chen, Bing Du, Xiaodong Zhang, Hai Zhong, Conggang Ning, Huimin Bai, Qian Li, Ruqing Pan, Baocheng Zhou and Hanjie Hu

Materials 2022, 15(22), 8013; https://doi.org/10.3390/ma15228013 - 13 Nov 2022

Cited by 9 | Viewed by 2234

Abstract

In this paper, the shear strength of adhesively bonded single-lap joints were experimentally and numerically investigated. Based on the validated simulation, the effects of lap length, adhesive layer thickness, adhesive layer shape, adhesive layer overflow length, and laminate lay-up on the shear strength of adhesively bonded single-lap joints were studied. The load-displacement curves and shear strength under different parameters were compared. It was shown that the shear strength of single-lap joints gradually decreases with the increase of lap length and adhesive layer thickness, which were 53.83% and 16.15%, respectively. Considering the potential condition in fabrication, the adhesive layer shape and adhesive layer overflow length were also investigated. The adhesive with normal and triangle shape owned the comparable shear strength, which was higher than the arc one. The shear strength increased by 19.37% from 18.43 MPa to 22.00 MPa with increasing the adhesive layer overflow length to 50% of lap length. It was beneficial for shear strength to increase the adhesive layer overflow length to 50% of lap length. Among the selected four lay-ups, [0]_16s had the highest shear strength, which was nearly 3 times greater than the one of [90]_16s. In the real process preparation, increasing the number of 0° layers, selecting the appropriate lap length and thickness of the adhesive layer, and controlling the shape and length of the adhesive layer overflow are of great help to improve the tensile shear strength of the single-lap glue joint. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies of Thermoplastic Composites)

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