Role of resin percolation in gap filling mechanisms during the thin ply thermosetting automated tape placement process

Šimáček, Pavel; Kermani, Navid Niknafs; Gargitter, Verena; Advani, Suresh G.

doi:10.1016/j.compositesa.2021.106677

Cited by 12 publications

(9 citation statements)

References 25 publications

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“…This local redistribution of resin is a similar mechanism to the one responsible for healing between plies [85]. However, and contrary to thermosets [86] (viscosities in the 1-10 Pa.s range [8]), the viscosity of thermoplastics is generally high at the processing temperature (100-1000 Pa.s [87]). For CFRTP with a fiber volume fraction close to 60%, the fibers are highly packed and thus, percolation through the fiber network will occur over times much higher than the other flow mechanisms [85].…”

Section: Matrix Percolationmentioning

confidence: 93%

“…Finally, defects are induced when steering tapes during AFP process, due to the roller imperfections. For straight steered tapes, gaps and overlaps are mainly generated [86,120,145,146], preventing from "in-situ" consolidation. Gaps create a local reduction in the laminate thickness whereas overlaps locally increase it.…”

Section: Optimization Of the Consolidation Processmentioning

confidence: 99%

“…Rajasekaran et al [151] also showed that decreasing the steering radius below 400 mm decreases the lap shear strength (LSS) from 21 MPa to 15 MPa, far below the LSS of autoclave processed samples (49 MPa). An additional processing step, as suggested by Kermani et al [120] is then often necessary to fill these gaps [86] and obtain a well-consolidated composite.…”

Section: Optimization Of the Consolidation Processmentioning

confidence: 99%

See 2 more Smart Citations

Consolidation of continuous-carbon-fiber-reinforced PAEK composites: a review

Arquier

Iliopoulos

Régnier

et al. 2022

Materials Today Communications

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Section: Matrix Percolationmentioning

confidence: 93%

Section: Optimization Of the Consolidation Processmentioning

confidence: 99%

Section: Optimization Of the Consolidation Processmentioning

confidence: 99%

See 1 more Smart Citation

Consolidation of continuous-carbon-fiber-reinforced PAEK composites: a review

Arquier

Iliopoulos

Régnier

et al. 2022

Materials Today Communications

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“…They occur between the adjacent prepreg tapes and have been studied by many researchers. 2,10,11,12,13,14,15,16,17 In this work, we used a thin and narrow tape which is approximately ¼’’ (6.35 mm) wide and 70 µm (0.07 mm) in thickness. As our tape is narrow and thin, it requires many layup iterations to build up to the required dimensions which increases the probability of gaps and overlaps that can lead to an adverse effect on the quality of the manufactured composite part.…”

Section: Introductionmentioning

confidence: 99%

Characterization and comparison of thin ply IM7/8552 composites processed by automated tape placement and hand layup

Balaga

Gargitter

Crane

et al. 2023

Journal of Composite Materials

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Manufacturing of large composite structures is labor-intensive and challenging. Traditional processing methods can be replaced by automated approaches such as Automated Tape Placement (ATP). The focal point of this effort is on thin-ply thermoset prepreg materials which have shown better resistance to damage tolerance under applied stress when compared to standard ply-thickness materials in recent times. However, composites processed by thin-ply materials require more placement iterations to achieve the same net volume of coverage as the standard ply-thickness materials. This can increase the probability of placement defects such as gaps and overlaps, which may degrade the mechanical performance of the composite. Modifications to the existing ATP system are made to address the issues of placement defects, which resulted in improved accuracy for thin ply placement. Unidirectional and quasi-isotropic panels are fabricated from 12’’ wide unidirectional prepreg sheet with the conventional hand layup (CHL) method for the baseline property comparison with panels fabricated by the ATP process using a ¼’’ wide slit tape. This paper investigates the effects of processing defects and material variability on the mechanical properties such as tensile, Open hole tension and Bearing tests of thin ply composites. In addition, the microstructure of the fabricated thin-ply composite panels is analysed using ultrasonic C-scans and confocal microscopy to examine the processing and material quality.

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“…As a result, various experimental evaluations of consolidation deformation have been conducted for many years to clarify the deformation mechanism [7][8][9][10]. Simulation models for predicting consolidation deformation have also been developed, and their validity has been verified by comparison with experiments [11][12][13][14][15][16]. However, most experimental evaluations to date have measured the shape of composite samples after curing and have been unable to accurately evaluate shape changes during consolidation.…”

Section: Introductionmentioning

confidence: 99%

Strip-Type Embeddable Shape Sensor Based on Fiber Optics for In Situ Composite Consolidation Monitoring

Minakuchi

Niwa

Takeda

2022

Sensors

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Carbon fibers and resin used in manufacturing carbon fiber-reinforced plastic composite structures flow before the resin solidifies, resulting in disrupted fiber orientation and non-uniform thickness. This process, known as consolidation, is critical for the quality of the composite structure, but no technology exists to measure the deformation in situ. This study proposes a strip-type embeddable shape sensor based on fiber optics for in situ monitoring of consolidation deformation. The sensor consists of a thin, flexible sheet with optical fibers embedded in the upper and lower surfaces of the sheet, and it can monitor out-of-plane bending deformation in composite materials during consolidation. Finite element analysis and experiments are used to evaluate the basic performance of the shape sensor before it is applied to composite gap/lap monitoring. For the first time, the relaxation of consolidation deformation due to the flow of fiber-resin suspension is measured. The proposed sensor will be a powerful tool for elucidating consolidation mechanisms and for validating composite manufacturing simulations.

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Role of resin percolation in gap filling mechanisms during the thin ply thermosetting automated tape placement process

Cited by 12 publications

References 25 publications

Consolidation of continuous-carbon-fiber-reinforced PAEK composites: a review

Consolidation of continuous-carbon-fiber-reinforced PAEK composites: a review

Characterization and comparison of thin ply IM7/8552 composites processed by automated tape placement and hand layup

Strip-Type Embeddable Shape Sensor Based on Fiber Optics for In Situ Composite Consolidation Monitoring

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