Flow properties of tailored net-shape thermoplastic composite preforms

S. T. Jespersen; F. Baudry; M. D. Wakeman; V. Michaud; P. Blanchard; R. Norris; J. A.E. Månson

doi:10.1007/s10443-009-9103-9

Flow properties of tailored net-shape thermoplastic composite preforms

S. T. Jespersen, F. Baudry, M. D. Wakeman, V. Michaud, P. Blanchard, R. Norris, J. A.E. Månson

Carbon and Composites

Research output: Contribution to journal › Article › peer-review

2 Scopus citations

Abstract

A novel thermoplastic programmable preforming process, TP-P4, has been used to manufacture preforms for non-isothermal compression molding. Commingled glass and polypropylene yarns are deposited by robot onto a vacuum screen, followed by a heat-setting operation to stabilize the as-placed yarns for subsequent handling. After an optional additional preconsolidation stage, the preforms are molded by preheating and subsequent press forming in a shear edge tool. The in- and out-of-plane flow capabilities of the material were investigated, and compared to those of 40∈_wt% Glass Mat Thermoplastics (GMTs). Although the TP-P4 material has a fiber fraction of 60∈_wt%, the material could be processed to fill 77 mm deep ribs with a thickness of 3 mm, indicative of complex part production. The pressure requirements for out-of-plane flow were shown to depend on the fiber length and fiber alignment. Segregation phenomena were found to be less severe with TP-P4 than with GMT material.

Original language	English
Pages (from-to)	331-344
Number of pages	14
Journal	Applied Composite Materials
Volume	16
Issue number	6
DOIs	https://doi.org/10.1007/s10443-009-9103-9
State	Published - Dec 2009

Funding

Acknowledgements This work was supported by the EPFL and the Automotive Composites Consortium comprising Daimler Chrysler, Ford Motor Company, General Motors and the US department of energy and US Council for Automotive research (USCAR). The authors wish to thank J.Carron, D.May, D.Schmäh, L. Kämpfer and G.Pasche from the EPFL, J.Dahl, G.Smith, M.DeBolt, R.Cooper and D.Houston from Ford Motor Co., S.A.Iobst from GM and K.D.Yarborough and R.D.Lomax from Oak Ridge National labs as well as C.Ducret from Vetrotex. The authors would also like to acknowledge Quadrant for supplying GMT materials.

Funders	Funder number
Automotive Composites Consortium comprising Daimler Chrysler
Council for Automotive research
USCAR
U.S. Department of Energy
Ford Motor Company
General Motors of Canada
École Polytechnique Fédérale de Lausanne

Keywords

Commingled yarns
Composites
Consolidation
Preforming
Thermoplastic

Access to Document

10.1007/s10443-009-9103-9

Cite this

@article{9674952f8bae4e95908f331006cc1d47,

title = "Flow properties of tailored net-shape thermoplastic composite preforms",

abstract = "A novel thermoplastic programmable preforming process, TP-P4, has been used to manufacture preforms for non-isothermal compression molding. Commingled glass and polypropylene yarns are deposited by robot onto a vacuum screen, followed by a heat-setting operation to stabilize the as-placed yarns for subsequent handling. After an optional additional preconsolidation stage, the preforms are molded by preheating and subsequent press forming in a shear edge tool. The in- and out-of-plane flow capabilities of the material were investigated, and compared to those of 40∈wt% Glass Mat Thermoplastics (GMTs). Although the TP-P4 material has a fiber fraction of 60∈wt%, the material could be processed to fill 77 mm deep ribs with a thickness of 3 mm, indicative of complex part production. The pressure requirements for out-of-plane flow were shown to depend on the fiber length and fiber alignment. Segregation phenomena were found to be less severe with TP-P4 than with GMT material.",

keywords = "Commingled yarns, Composites, Consolidation, Preforming, Thermoplastic",

author = "Jespersen, {S. T.} and F. Baudry and Wakeman, {M. D.} and V. Michaud and P. Blanchard and R. Norris and M{\aa}nson, {J. A.E.}",

year = "2009",

month = dec,

doi = "10.1007/s10443-009-9103-9",

language = "English",

volume = "16",

pages = "331--344",

journal = "Applied Composite Materials",

issn = "0929-189X",

publisher = "Springer",

number = "6",

}

TY - JOUR

T1 - Flow properties of tailored net-shape thermoplastic composite preforms

AU - Jespersen, S. T.

AU - Baudry, F.

AU - Wakeman, M. D.

AU - Michaud, V.

AU - Blanchard, P.

AU - Norris, R.

AU - Månson, J. A.E.

PY - 2009/12

Y1 - 2009/12

N2 - A novel thermoplastic programmable preforming process, TP-P4, has been used to manufacture preforms for non-isothermal compression molding. Commingled glass and polypropylene yarns are deposited by robot onto a vacuum screen, followed by a heat-setting operation to stabilize the as-placed yarns for subsequent handling. After an optional additional preconsolidation stage, the preforms are molded by preheating and subsequent press forming in a shear edge tool. The in- and out-of-plane flow capabilities of the material were investigated, and compared to those of 40∈wt% Glass Mat Thermoplastics (GMTs). Although the TP-P4 material has a fiber fraction of 60∈wt%, the material could be processed to fill 77 mm deep ribs with a thickness of 3 mm, indicative of complex part production. The pressure requirements for out-of-plane flow were shown to depend on the fiber length and fiber alignment. Segregation phenomena were found to be less severe with TP-P4 than with GMT material.

AB - A novel thermoplastic programmable preforming process, TP-P4, has been used to manufacture preforms for non-isothermal compression molding. Commingled glass and polypropylene yarns are deposited by robot onto a vacuum screen, followed by a heat-setting operation to stabilize the as-placed yarns for subsequent handling. After an optional additional preconsolidation stage, the preforms are molded by preheating and subsequent press forming in a shear edge tool. The in- and out-of-plane flow capabilities of the material were investigated, and compared to those of 40∈wt% Glass Mat Thermoplastics (GMTs). Although the TP-P4 material has a fiber fraction of 60∈wt%, the material could be processed to fill 77 mm deep ribs with a thickness of 3 mm, indicative of complex part production. The pressure requirements for out-of-plane flow were shown to depend on the fiber length and fiber alignment. Segregation phenomena were found to be less severe with TP-P4 than with GMT material.

KW - Commingled yarns

KW - Composites

KW - Consolidation

KW - Preforming

KW - Thermoplastic

UR - http://www.scopus.com/inward/record.url?scp=71449113944&partnerID=8YFLogxK

U2 - 10.1007/s10443-009-9103-9

DO - 10.1007/s10443-009-9103-9

M3 - Article

AN - SCOPUS:71449113944

SN - 0929-189X

VL - 16

SP - 331

EP - 344

JO - Applied Composite Materials

JF - Applied Composite Materials

IS - 6

ER -

Flow properties of tailored net-shape thermoplastic composite preforms

Abstract

Funding

Keywords

Access to Document

Other files and links

Fingerprint

Cite this