Issues Related to Processability during the Manufacture of Thermoplastic Composites Using On-Line Consolidation Techniques

Abstract

The on-line consolidation of thermoplastic composites is a relatively new technology that can be used to manufacture composite parts with complex geometries. The localized melting/solidification technique employed in this process can reduce the residual stresses and allow for improved dimensional stability and performance. An additional advantage of this technique is the elimination of the curing steps which are necessary in the processing of thermoset-matrix composites. This article presents the effects of processing parameters on processability in on-line consolidation of thermoplastic composites for tape-laying and filament-winding processes employing anisotropic thermal analyses. The results show that the heater size, preheating conditions, and tow thickness can significantly affect the processing window which, in turn, affects the production rate and the quality of the parts.

Effects of Geometric Optimization of Plug-Supported End-Caps on the Performance of Thick Thermoplastic Composite Pressure Vessels Under External Hydrostatic Pressure

“…However, thermoplastic composites are endothermic, and an in-situ thermoplastic composite filament winding technique can be used to manufacture thicksection pressure hulls. The consolidation can be achieved during the winding using in-situ heat sources and a consolidation pressure roller [7][8][9][10][11][12][13][14][15][16][17]. On-line consolidation can considerably reduce the residual stresses in the structure [18][19][20], which yields final products with better quality and performance, when a localized consolidation heat source system is used.…”

Design, Analysis, Manufacture, and Test of APC-2/AS4 Thermoplastic Composite Pressure Vessels for Deep Water Marine Applications

“…The larger the size of the processing window, the easier to control the processing and quality of the manufactured parts [18][19][20][21][22]. Finally, the compaction roller (shown schematically in Figure 19 and given in Figure 20) should apply enough pressure on the lay-down point to facilitate the consolidation process for the incoming composite tape on to the substrate [22][23][24][25].…”

Filament Winding of Co-Extruded Polypropylene Tapes for Fully Recyclable All-Polypropylene Composite Products

“…In addition, if higher productivity is required, the three steps of the process (winding, heating, separation from the mandrel) can be fully automated without a single operator intervention. It is a different process to standard thermoplastic filament-winding process in which the prepreg tapes of the commingled bundle are typically preheated locally by hot air, flame or laser heating before reaching the mandrel, where pressure is usually applied at the contact point [23,24]. The winding speed for all-PP composites can be substantially higher than for conventional thermoplastic composite filament winding processes as no heating or cooling is necessary during winding.…”