Statistical Study of the Process Parameters for Achieving Continuous Consolidation of a Thermoplastic Composite

Abstract

Manufacturing components using thermoplastic composite materials necessitates a judicious balance among fabrication parameters, cost considerations and the ultimate quality of the elements produced. Continuous manufacturing technologies, exemplified by methods such as continuous compressing molding and glide forming, seek to revolutionize production through their continuous processing approach. This study aimed to investigate the effects different process parameters have on the final quality of the manufactured parts when a continuous manufacturing technology, such as glide forming, is applied to thermoplastic composite materials. An experimental rig was designed, and 19 samples were prepared using a unidirectional-carbon-fiber-reinforced LM-PAEK (low-melting polyaryletherketone) composite. The process parameters studied were temperature, pressure and forming speed. The quality of the final parts was evaluated based on their thickness and consolidation levels. The findings underscore the feasibility of leveraging continuous manufacturing technologies for producing components using thermoplastic composite materials, but the process parameters must be carefully controlled to ensure the quality of the final part. The models obtained could be used as a post-processing tool to predict thickness and consolidation levels when simulating the manufacture of a component on macroscale levels. Further research is needed to optimize the process parameters and study their effects on other thermoplastic composite materials.

Bidirectional-Reinforced Carbon Fiber/Polyether-Ether-Ketone Composite Thin-Walled Pipes via Pultrusion-Winding for On-Orbit Additive Manufacturing

“…In 2013, Tethers Unlimited proposed the concept project "SpiderFab", which combines 3D printing technology with the aerospace industry to manufacture large space structures in space like a spider web [9]. Compared with thermosetting composites, the thermoplastic composites have shown higher strength, longer life, better corrosion resistance and green recyclability [10][11][12][13][14][15][16]. The applications of high-performance thermoplastic resins such as PEEK have been widely studied.…”