Laser Joining of Continuous Glass Fiber Composite Pre-Forms

Abstract

A laser fusion joining method is investigated for the purpose of through thickness strengthening of fiber pre-forms used in the vacuum infusion fabrication of thick composite structures. Laser joining is achieved without filler materials to replace adhesives, pins or stitches used in conventional composite fabrication.A two step joining process is developed to fuse fibers within a single bundle and between multiple fiber bundles. Finite element analysis is used to investigate the joint strength with respect to joint morphology. Joint strength is found to be a function of the fiber contact angle and packing density at the joint interface. Tensile tests show that laser joined fiber bundles exhibit higher strength than comparable fastening methods. Lessons learned from the axial joining of fiber bundles are applied to joining in the radial and thickness directions of 3d pre-form architectures. Flow induced joint morphology and densification effects observed in the axial direction indicate the need for a two step joining process in the thickness direction. Fiber compaction effects on joint strength in the axial direction motivate the need for high fiber packing fraction at joint interfaces in the thickness direction. INTRODUCTIONComposite pre-preg fabrication involves placing densely packed resin infused tapes of reinforcement fibers in layers (laminates) and then curing to produce thin shell structures. Composite components manufactured from pre-preg processes exhibit high fiber packing fraction and high strength along the fiber directions, but offer little strength perpendicular to the fiber directions. Laminates of pre-preg construction contain no fiber reinforcements aligned in the thickness direction due to the layer by layer assembly process. Thus, pre-preg fabrication is undesirable for making composite parts requiring high through thickness strength and fracture toughness. One method for improving the through thickness strength of pre-preg constructed components is to insert metal pins through layers of pre-preg prior to curing [1,2]. Mechanical pinning increases through thickness strength, relying on matrix load transfer mechanisms between the fibers and pins. The insertion of metal pins into a stack of pre-preg lamina displaces the fibers in the lamina and introduces

Through thickness laser joining of continuous glass fiber fabric reinforcement

“…The simulation concurrently solves the compressible Navier Stokes equations for viscous fluid flow, phase field (Cahn Hilliard) equations for two phase immiscibility and velocity dependent heat equations, as described in a previous paper [17]. Phase, density and temperature evolution output from the multi physics model yield spatially resolved time dependent flow of glass with and without the addition of fill material.…”