Low-cost thermal reshaping of carbon fibre/PEEK thick sections: Experiments and simulations

Abstract

This study develops a new low-cost remoulding route to reshape thick composite waste. A coupled experimental and numerical methodology is proposed and applied to carbon fibre polyether ether ketone pipes from oil and gas industry. The experimental procedure concludes that sample flatness can be improved by up to 65% without using additional moulds and for relatively low pressures and processing temperatures, above the glass transition temperature but well below the material's melting point, minimising the energy consumption and cost of the process. Micro CT inspection reveals a significant reduction in local void content in regions subjected to transverse compression, ensuring the quality of the reshaped component. The capabilities and limitations of different processing parameters are assessed numerically. Guidelines for sustainable reshaping of composite waste for different applications are provided, opening the path for a new method of managing composite waste at a minimum cost.