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Search Results (5)

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Keywords = laser-assisted automated fiber placement

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15 pages, 3974 KB  
Article
Cast Polyamide 6 Molds as a Suitable Alternative to Metallic Molds for In Situ Automated Fiber Placement
by Fynn Atzler, Ines Mössinger, Jonathan Freund, Samuel Tröger, Ashley R. Chadwick, Simon Hümbert and Lukas Raps
J. Compos. Sci. 2025, 9(7), 367; https://doi.org/10.3390/jcs9070367 - 15 Jul 2025
Viewed by 3738
Abstract
Thermoplastic in situ Automated Fiber Placement (AFP) is an additive manufacturing method currently investigated for its suitability for the production of aerospace-grade composite structures. A considerable expense in this process is the manufacturing and preparation of a mold in which a composite part [...] Read more.
Thermoplastic in situ Automated Fiber Placement (AFP) is an additive manufacturing method currently investigated for its suitability for the production of aerospace-grade composite structures. A considerable expense in this process is the manufacturing and preparation of a mold in which a composite part can be manufactured. One approach to lowering these costs is the use of a 3D-printable thermoplastic mold. However, AFP lay-up on a 3D-printed mold differs from the usage of a traditional metallic mold in various aspects. Most notable is a reduced stiffness of the mold, a lower thermal conductivity of the mold, and the need for varied process parameters of the AFP process. This study focuses on the investigation of the difference in mechanical and morphological characteristics of laminates produced on metallic and polymeric molds. To this end, the tensile strength and the interlaminar shear strength of laminates manufactured on each substrate were measured and compared. Additionally, morphological analysis using scanning electron microscopy and differential scanning calorimetry was performed to compare the crystallinity in laminates. No statistically significant difference in mechanical or morphological properties was found. Thus, thermoplastics were shown to be a suitable material for non-heated molds to manufacture in situ AFP composites. Full article
(This article belongs to the Section Composites Manufacturing and Processing)
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13 pages, 12217 KB  
Article
The Effect of Repass Treatment on the Mechanical Properties and Microstructure of CF/PEKK Thermoplastic Composite Laminates Manufactured Using Laser-Assisted Automated Fiber Placement
by Xi Zhang, Xiaodong He, Hualian Li and Shenglai Wang
Polymers 2025, 17(1), 73; https://doi.org/10.3390/polym17010073 - 30 Dec 2024
Cited by 1 | Viewed by 2363
Abstract
The emerging thermoplastic composite material PEKK exhibits superior thermal stability compared to PEEK. In this work, CF/PEKK laminates were fabricated using laser-assisted heating in AFP, and the effects of repass treatment on the mechanical properties and microstructure of the laminates were compared. The [...] Read more.
The emerging thermoplastic composite material PEKK exhibits superior thermal stability compared to PEEK. In this work, CF/PEKK laminates were fabricated using laser-assisted heating in AFP, and the effects of repass treatment on the mechanical properties and microstructure of the laminates were compared. The results show that after a single repass treatment, the tensile strength of the laminates increased by 28.39%, while the interlaminar shear strength increased by 11.9%, likely due to the distinct load-bearing components under the two loading conditions. Additionally, the repass treatment significantly improves the fiber/resin interface and surface roughness of the laminates. Full article
(This article belongs to the Section Polymer Composites and Nanocomposites)
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13 pages, 6356 KB  
Article
The Effect of Resin Interleafing on the Wedge Peel Strength of CF/PEEK Manufactured by Laser-Assisted In Situ Consolidation
by Ruozhou Wang, Entao Xu and Liwei Wen
Coatings 2024, 14(5), 635; https://doi.org/10.3390/coatings14050635 - 17 May 2024
Cited by 3 | Viewed by 2328
Abstract
In this work, a novel approach involving coating fine PEEK powder on prepreg is introduced to improve wedge peel strength and reduce interlaminar voids. CF/PEEK laminates with resin interleaving are in situ consolidated by laser-assisted fiber placement. The morphology of the powdered surface [...] Read more.
In this work, a novel approach involving coating fine PEEK powder on prepreg is introduced to improve wedge peel strength and reduce interlaminar voids. CF/PEEK laminates with resin interleaving are in situ consolidated by laser-assisted fiber placement. The morphology of the powdered surface is obtained using an optical profilometer, and the surface roughness and volume of added resin are calculated accordingly. Interface and surface temperature are measured during the layup process. Thermal history indicates that very short bonding time is the dominating factor for voids and limited interlayer strength. Laminate porosity and microscopic features are characterized with an optical microscope. The porosity of resin-interleaved laminates decreases to 3.7%, while the resin content only increases by 4.5% in the meantime. This is because interlayer resin particles rapidly melt under laser heating and quickly fill the voids between layers. The wedge peel strength of resin-interleaved laminates can increase by 30.1% without a repass treatment. This could be attributed to the increase in resin intimate contact and reduction in interlayer voids. Full article
(This article belongs to the Special Issue Surface Science of Degradation and Surface Protection)
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17 pages, 5106 KB  
Article
Effect of Flashlamp Heating System Parameters on the Wedge Peel Strength of Thermoplastic Carbon Fiber Tape in the Automated Tape Placement Process
by Alexander Legenstein and Ewald Fauster
J. Manuf. Mater. Process. 2024, 8(3), 91; https://doi.org/10.3390/jmmp8030091 - 29 Apr 2024
Cited by 8 | Viewed by 3165
Abstract
Laser-assisted automated tape placement systems are currently the state of the art regarding thermoplastic tape placement. Flashlamp heating systems are rather new in this field of application and offer high energy density with low safety requirements and moderate costs compared to laser-assisted automated [...] Read more.
Laser-assisted automated tape placement systems are currently the state of the art regarding thermoplastic tape placement. Flashlamp heating systems are rather new in this field of application and offer high energy density with low safety requirements and moderate costs compared to laser-assisted automated tape placement systems. In this study, the effect of processing parameters on interlaminar bonding of carbon fiber-reinforced polyamide 6 tapes is investigated using a flashlamp heating system. The temperature during placement is monitored using an infrared camera, and the bonding strength is characterized by a wedge peel test. The bonding quality of the tapes placed between 210 °C and 330 °C at a lay-up speed of 50 mm/s is investigated. Thermogravimetric analysis, differential scanning calorimetry, and micrographs are used to investigate the material properties and effects of the processing conditions on the thermophysical properties and geometric properties of the tape. No significant changes in the thermophysical or geometric properties were found. Moisture within the tapes and staining of the quartz guides of the flashlamp system have significant influence on the bonding strength. The highest wedge peel strength of dried tapes was found at around 330 °C. Full article
(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)
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12 pages, 5455 KB  
Article
Influence of a Dynamic Consolidation Force on In Situ Consolidation Quality of Thermoplastic Composite Laminate
by Berend Denkena, Carsten Schmidt, Maximilian Kaczemirzk and Max Schwinn
J. Compos. Sci. 2021, 5(3), 88; https://doi.org/10.3390/jcs5030088 - 22 Mar 2021
Cited by 6 | Viewed by 4423
Abstract
For achieving high quality of in situ consolidation in thermoplastic Automated Fiber Placement, an approach is presented in this research work. The approach deals with the combination of material pre-heating and sub-ultrasonic vibration treatment. Therefore, this research work investigates the influence of frequency [...] Read more.
For achieving high quality of in situ consolidation in thermoplastic Automated Fiber Placement, an approach is presented in this research work. The approach deals with the combination of material pre-heating and sub-ultrasonic vibration treatment. Therefore, this research work investigates the influence of frequency dependent consolidation pressure on the consolidation quality. A simplified experimental setup was developed that uses resistance electrical heating instead of the laser to establish the thermal consolidation condition in a universal testing machine. Consolidation experiments with frequencies up to 1 kHz were conducted. The manufactured specimens are examined using laser scanning microscopy to evaluate the bonding interface and differential scanning calorimetry to evaluate the degree of crystallinity. Additionally, the vibration-assisted specimens were compared to specimens manufactured with static consolidation pressure only. As a result of the experimental study, the interlaminar pore fraction and degree of compaction show a positive dependency to higher frequencies. The porosity decreases from 0.60% to 0.13% while the degree of compaction increases from 8.64% to 12.49% when increasing the vibration frequency up to 1 kHz. The differential scanning calorimetry experiments show that the crystallinity of the matrix is not affected by vibration-assisted consolidation. Full article
(This article belongs to the Special Issue Thermal Behavior of Thermoset Composites)
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