Temperature variation during continuous laser-assisted adjacent hoop winding of type-IV pressure vessels: An experimental analysis

Abstract

Laser-assisted tape winding is an automated process to produce tubular or tube-like continuous fiber-reinforced polymer composites by winding a tape around a mandrel or liner. Placing additional layers on a previously heated substrate and variation in material and process parameters causes a variation in the bonding temperature of fiber-reinforced thermoplastic tapes which need to be understood and described well in order to have a reliable manufacturing process. In order to quantify the variation in this critical bonding temperature, a comprehensive temperature analysis of an adjacent hoop winding process of type-IV pressure vessels is performed. A total of five tanks are manufactured in which three glass/HDPE tapes are placed on an HDPE liner. The tape and substrate temperatures, roller force and tape feeding velocity are measured. The coefficient of variation for each round is characterized for the first time. According to the statistical analysis, the coefficient of variation in substrate temperature is found to be approximately 4.8–8.8% which is larger than the coefficient of variation of the tape temperature which is 2.1–7.8%. The coefficient of variations of the substrate temperatures in the third round decrease as compared with the coefficient of variations in the second round mainly due to the change in gap/overlap behavior of the deposited tapes. Fourier and thermographic analysis evince that the geometrical disturbances such as unroundness and eccentricity have a direct effect on the temperature variation. In addition to the temperature feedback control, a real-time object detection technique with deep learning algorithms can be used to mitigate the unwanted temperature variation and to have a more reliable thermal history.

On the temperature evolution during continuous laser-assisted tape winding of multiple C/PEEK layers: The effect of roller deformation

“…The maximum and minimum variation in substrate and tape temperatures among the three winding experiments was found to be 80 • C for layer-22 and 10 • C for layer-7, respectively. The possible reasons for the variations in the temperature measurements within three rings production could be related to the local variation in material properties of the prepreg [44], local deconsolidation in the heated region and varying emissivity coefficient as a function of temperature [19] which was constant in the current configuration of the thermal camera.…”

“…The ATW technique is highly automated and used to manufacture tubular-like structures such as flywheel rotors [21,38], tanks for energy storage, pipes for oil and gas industry [29,44], tubes for bikes, etc. The heating source can be a hot gas torch [12,13,22], infrared lamp [4,16,18], near-infrared (NIR) diode lasers [5,10,11,31], and recently LED heating [25].…”

Non-uniform crystallinity and temperature distribution during adjacent laser-assisted tape winding process of carbon/PA12 pipes

“…Several studies have focused on monitoring the temperature during AFP or ATW processes where multiple tapes are deposited on top of each other [9,11,22,[35][36][37]. However, the critical analysis of the adjacent AFP/ATW process of fiber-reinforced polymer composites has received less attention in the literature.…”

Influence Mechanism and Optimization Analysis of Technological Parameters for the Composite Prepreg Tape Winding Process

“…The wound product will be cured and demolded to become the final product. Studies have shown that the process parameters during the winding process, such as heating temperature, tape tension and roller pressure and winding speed have a significant effect on the mechanical property of the composite wound products [12][13][14][15][16][17]. As an important index to characterize the mechanical properties of wound products, hoop tensile strength is employed to reflect the ability of composite cylindrical parts to resist hoop tensile failure.…”

“…In Nath's article [14], four control factors machine speed, roller pressure, tape tension and tape temperature were investigated for the tape winding process. Meanwhile, processing temperature, winding speed and compaction pressure were selected as the key parameters to study for tape winding process according to Dai et al [15] and Zaami et al [16]. However, three parameters including tape tension, roller pressure and temperature were analyzed for developing a NC tape winding machine from a research of Shi et al [17].…”