Rapid processing of net-shape thermoplastic planar-random composite preforms

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

doi:10.1007/s10443-008-9078-y

Rapid processing of net-shape thermoplastic planar-random composite preforms

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

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

12 Scopus citations

Abstract

A novel thermoplastic composite preforming and moulding process is investigated to target cost issues in textile composite processing associated with trim waste, and the limited mechanical properties of current bulk flow-moulding composites. The thermoplastic programmable powdered preforming process (TP-P4) uses commingled glass and polypropylene yarns, which are cut to length before air assisted deposition onto a vacuum screen, enabling local preform areal weight tailoring. The as-placed fibres are heat-set for improved handling before an optional preconsolidation stage. The preforms are then preheated and press formed to obtain the final part. The process stages are examined to optimize part quality and throughput versus processing parameters. A viable processing route is proposed with typical cycle times below 40 s (for a plate 0.5∈×∈0.5 m², weighing 2 kg), enabling high production capacity from one line. The mechanical performance is shown to surpass that of 40 wt.% GMT and has properties equivalent to those of 40 wt.% GMTex at both 20°C and 80°C.

Original language	English
Pages (from-to)	55-71
Number of pages	17
Journal	Applied Composite Materials
Volume	16
Issue number	1
DOIs	https://doi.org/10.1007/s10443-008-9078-y
State	Published - Feb 2009
Externally published	Yes

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, 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 General Motors and K.D. Yarborough and R.D. Lomax from Oak Ridge National lab as well as C. Ducret from Owens Corning. The authors would also like to acknowledge the National Composites Center for aid with the processing.

Keywords

Net-shape
Preforming
Stamp forming
Thermoplastic composites

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10.1007/s10443-008-9078-y

Cite this

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title = "Rapid processing of net-shape thermoplastic planar-random composite preforms",

abstract = "A novel thermoplastic composite preforming and moulding process is investigated to target cost issues in textile composite processing associated with trim waste, and the limited mechanical properties of current bulk flow-moulding composites. The thermoplastic programmable powdered preforming process (TP-P4) uses commingled glass and polypropylene yarns, which are cut to length before air assisted deposition onto a vacuum screen, enabling local preform areal weight tailoring. The as-placed fibres are heat-set for improved handling before an optional preconsolidation stage. The preforms are then preheated and press formed to obtain the final part. The process stages are examined to optimize part quality and throughput versus processing parameters. A viable processing route is proposed with typical cycle times below 40 s (for a plate 0.5∈×∈0.5 m2, weighing 2 kg), enabling high production capacity from one line. The mechanical performance is shown to surpass that of 40 wt.\% GMT and has properties equivalent to those of 40 wt.\% GMTex at both 20°C and 80°C.",

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AU - Jespersen, S. T.

AU - Baudry, F.

AU - Schmäh, D.

AU - Wakeman, M. D.

AU - Michaud, V.

AU - Blanchard, P.

AU - Norris, R. E.

AU - Månson, J. A.E.

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N2 - A novel thermoplastic composite preforming and moulding process is investigated to target cost issues in textile composite processing associated with trim waste, and the limited mechanical properties of current bulk flow-moulding composites. The thermoplastic programmable powdered preforming process (TP-P4) uses commingled glass and polypropylene yarns, which are cut to length before air assisted deposition onto a vacuum screen, enabling local preform areal weight tailoring. The as-placed fibres are heat-set for improved handling before an optional preconsolidation stage. The preforms are then preheated and press formed to obtain the final part. The process stages are examined to optimize part quality and throughput versus processing parameters. A viable processing route is proposed with typical cycle times below 40 s (for a plate 0.5∈×∈0.5 m2, weighing 2 kg), enabling high production capacity from one line. The mechanical performance is shown to surpass that of 40 wt.% GMT and has properties equivalent to those of 40 wt.% GMTex at both 20°C and 80°C.

AB - A novel thermoplastic composite preforming and moulding process is investigated to target cost issues in textile composite processing associated with trim waste, and the limited mechanical properties of current bulk flow-moulding composites. The thermoplastic programmable powdered preforming process (TP-P4) uses commingled glass and polypropylene yarns, which are cut to length before air assisted deposition onto a vacuum screen, enabling local preform areal weight tailoring. The as-placed fibres are heat-set for improved handling before an optional preconsolidation stage. The preforms are then preheated and press formed to obtain the final part. The process stages are examined to optimize part quality and throughput versus processing parameters. A viable processing route is proposed with typical cycle times below 40 s (for a plate 0.5∈×∈0.5 m2, weighing 2 kg), enabling high production capacity from one line. The mechanical performance is shown to surpass that of 40 wt.% GMT and has properties equivalent to those of 40 wt.% GMTex at both 20°C and 80°C.

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KW - Stamp forming

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Rapid processing of net-shape thermoplastic planar-random composite preforms

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Keywords

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