SAMPE Journal最新文献_第2页

Automated Manufacturing of Grid Stiffened Panels with Radically Reduced Tooling 利用大幅减少的工具自动制造网格加劲板

IF 0.2 4区材料科学

SAMPE Journal Pub Date : 2024-01-01 DOI: 10.33599/sj.v60no1.03

H. Ratkai, S. Tanu, Donald W. Radford

{"title":"Automated Manufacturing of Grid Stiffened Panels with Radically Reduced Tooling","authors":"H. Ratkai, S. Tanu, Donald W. Radford","doi":"10.33599/sj.v60no1.03","DOIUrl":"https://doi.org/10.33599/sj.v60no1.03","url":null,"abstract":"Grid stiffened continuous fiber reinforced composite panels are an attractive option for creating lightweight structures due to the tailorability for various applications and the resulting high specific properties. However, the panel stiffeners and stiffener intersections result in high tooling complexity and correspondingly high cost of implementation. These factors have limited the impact of such structures in the composites industry. Previous research has demonstrated the ability to produce high quality, high aspect ratio beams, representative of individual grid stiffeners, using E-glass/PET comingled tow via direct digital manufacturing. Further, prior preliminary efforts have demonstrated the potential to use the same approach to manufacture grid intersections that have continuous fiber in both directions. To expand on the previous efforts in grid stiffeners produced by direct digital manufacture with radically reduced tooling requirements, this effort compares two methods of providing positioning and consolidation, nozzle vs. roller. Both processes are based on a commingled yarn feedstock. The extrusion through a nozzle has been shown to enable grid intersection control through local variations in applied consolidation and serves as the baseline process. However, this approach requires a continuous placement path to create the complete grid stiffened panel as no mechanism for cutting and restarting has been implemented. Alternatively, a newly developed placement head incorporating cut and refeed, mounted to a 6-axis robot, offers the potential of improved path placement efficiency. The two techniques are used to produce similar grid composite stiffeners to evaluate the effectiveness of producing the grid intersections. Rate of deposition of the two end effectors are compared and the quality of the associated grid stiffeners, and intersections, are determined through measurement of geometry, fiber volume fraction and void fraction.","PeriodicalId":49577,"journal":{"name":"SAMPE Journal","volume":null,"pages":null},"PeriodicalIF":0.2,"publicationDate":"2024-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140522878","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Automated Process Based on Functionalized Preform and Net-shape High Performance Resin Transfer Molding for High Volume Structural Applications 基于功能化预成型和网状高性能树脂传递模塑的自动化工艺，适用于大批量结构应用

IF 0.2 4区材料科学

SAMPE Journal Pub Date : 2024-01-01 DOI: 10.33599/sj.v60no1.01

Alexandre Hamlyn, Sophie Job

{"title":"Automated Process Based on Functionalized Preform and Net-shape High Performance Resin Transfer Molding for High Volume Structural Applications","authors":"Alexandre Hamlyn, Sophie Job","doi":"10.33599/sj.v60no1.01","DOIUrl":"https://doi.org/10.33599/sj.v60no1.01","url":null,"abstract":"In this paper, a new process is highlighted for mass production of composite structural parts for the automotive and high-volume aerospace markets. This process follows different steps: (1) Simulation of the process to optimize the design of the 3D part and its corresponding 2D blank, (2) High speed Automated Fiber Placement (AFP) of 2D tailored dry preform blanks made from direct fiber, online fiber spreading and binder application, (3) Preform functionalization to improve its formability and permeability, but also to make handling and trimming easier, (4) Forming of the 2D functionalized preform to 3D shape and net shape trimming, (5) Net shape preform impregnation with High-Pressure-Resin-Transfer-Molding (HP-RTM), thanks to excellent through thickness (z direction) permeability, and preform stability. To assess the process performance and resulting parts, 3D parts and 2D coupons were manufactured using the new developed preforms and Non-Crimp-Fabric (NCF), having in both cases the same fiber and matrix. The performances were evaluated all along the process steps and the results show improvements in several key process parameters, equivalent mechanical performances and increase surface quality, hence resulting in less effort for surface preparation.","PeriodicalId":49577,"journal":{"name":"SAMPE Journal","volume":null,"pages":null},"PeriodicalIF":0.2,"publicationDate":"2024-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140518226","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Thermal and Mechanical Characterization of 3D Printed Continuous Fiber Reinforced Composites 三维打印连续纤维增强复合材料的热学和力学特性分析

IF 0.2 4区材料科学

SAMPE Journal Pub Date : 2023-11-01 DOI: 10.33599/sj.v59no6.02

Andrew C. Abbott, J. Furmanski, G. P. Tandon, Hilmar Koerner, Dennis Butcher

引用次数: 0

Automated Fiber Placement Laminate Level Optimization for Mitigation of Through Thickness Defect Stacking 自动纤维铺放层级优化，减少厚度缺陷堆叠

IF 0.2 4区材料科学

SAMPE Journal Pub Date : 2023-11-01 DOI: 10.33599/sj.v59no6.03

N. Swingle, A. Brasington, J. Halbritter, R. Harik

引用次数: 0

Thermoplastic Composite Rate Enhanced Stiffened Skin: A Case Study 热塑性复合材料速率增强刚性表皮：案例研究

IF 0.2 4区材料科学

SAMPE Journal Pub Date : 2023-11-01 DOI: 10.33599/sj.v59no6.01

Joseph P. Heil, Mark A. Wadsworth, K. Dando, Ron E. Jones, Matt Tymes, Sam J Slater, Rodney E. Bahr, Bryan T. Bearden

引用次数: 0

A Novel additive manufacturing process for multi-matrix fiber reinforced composites 多基质纤维增强复合材料的新型快速成型制造工艺

IF 0.2 4区材料科学

SAMPE Journal Pub Date : 2023-11-01 DOI: 10.33599/sj.v59no6.04

Simon Konze, T. V. Lisbôa, Sascha Bruk, L. Bittrich, Markus Stommel, Martin Wildemann, Johannes Herold, A. Spickenheuer

{"title":"A Novel additive manufacturing process for multi-matrix fiber reinforced composites","authors":"Simon Konze, T. V. Lisbôa, Sascha Bruk, L. Bittrich, Markus Stommel, Martin Wildemann, Johannes Herold, A. Spickenheuer","doi":"10.33599/sj.v59no6.04","DOIUrl":"https://doi.org/10.33599/sj.v59no6.04","url":null,"abstract":"Integrating different matrices into fiber-reinforced plastics (FRP) offers great potential for general tailored functionalities. By locally integrating flexible matrix zones in otherwise stiff FRPs, both very stiff and flexible areas with properties such as bending and damping behavior can be achieved. A novel method for manufacturing these so-called multi-matrix composites (MMC) is presented in this work. Either manually or in an automated fashion a first matrix system is locally applied to fiber preforms. After curing these zones, all fiber areas that are still dry can be infiltrated with a second matrix system. In this manner a composite structure with different and defined matrix zones of almost any size and shape can be created. Experimentally, the integration of flexible polyurethane and stiff epoxy resin into glass fiber preforms was investigated, considering material compatibility and process precision. For an established process-chain, good infiltration quality with distinct transition zone between the matrices was verified, resulting in bending specimens showing deformation only in the regions of polyurethane elastomer matrix.","PeriodicalId":49577,"journal":{"name":"SAMPE Journal","volume":null,"pages":null},"PeriodicalIF":0.2,"publicationDate":"2023-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139301676","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Towards In-line Control of Continuous Resistance Welding for Joining Structural Thermoplastic Composites 结构热塑性复合材料连接连续电阻焊在线控制研究

4区材料科学

SAMPE Journal Pub Date : 2023-09-01 DOI: 10.33599/sj.v59no5.01

Marc Palardy-Sim, Julieta Barroeta Robles, Marc-André Octeau, Steven Roy, Ali Yousefpour, Stephen Atkinson, Scott Nesbitt, Reza Vaziri, Anoush Poursartip, Manuel Endrass, Lars Larsen, Michael Kupke

{"title":"Towards In-line Control of Continuous Resistance Welding for Joining Structural Thermoplastic Composites","authors":"Marc Palardy-Sim, Julieta Barroeta Robles, Marc-André Octeau, Steven Roy, Ali Yousefpour, Stephen Atkinson, Scott Nesbitt, Reza Vaziri, Anoush Poursartip, Manuel Endrass, Lars Larsen, Michael Kupke","doi":"10.33599/sj.v59no5.01","DOIUrl":"https://doi.org/10.33599/sj.v59no5.01","url":null,"abstract":"The continuous resistance welding (CRW) process consists of an end-effector which moves along the length of a weld seam, heating a conductive implant while compacting the joint locally throughout the melt and solidification stages of the thermoplastic material. The performance of the joint has been shown to be highly dependent on the process temperature at the weld interface; however, this cannot be measured directly during the process in a non-invasive manner. Other parameters such as boundary conditions, substructure properties, or part geometry may vary along the length of the weld. As such, a physics-based simulation is developed founded upon an “MSTEP” framework which defines how the materials (M), shape (S), tooling (T), and equipment (E) interact to determine the process (P). Detailed finite element (FE) models are developed for thermal analysis based on the weld geometry, boundary conditions, and previously developed and validated melt/crystallization models for the thermoplastic matrix. Experimental CRW tests are presented to validate simulations and calibrate suitable control variables.","PeriodicalId":49577,"journal":{"name":"SAMPE Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135298653","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Characterization of Magnetic Susceptor Heating Rate Due to Hysteresis Losses in Thermoplastic Welding 热塑性焊接中磁滞损耗引起的电纳加热速率表征

4区材料科学

SAMPE Journal Pub Date : 2023-09-01 DOI: 10.33599/sj.v59no5.02

Romain Martin, Martin Figueiredo, Christer Johansson, Jason R. Tavares, Martine Dubé

{"title":"Characterization of Magnetic Susceptor Heating Rate Due to Hysteresis Losses in Thermoplastic Welding","authors":"Romain Martin, Martin Figueiredo, Christer Johansson, Jason R. Tavares, Martine Dubé","doi":"10.33599/sj.v59no5.02","DOIUrl":"https://doi.org/10.33599/sj.v59no5.02","url":null,"abstract":"Welding techniques are emerging as a new method to join thermoplastic composite parts. They present a fast and efficient alternative to adhesives and mechanical fasteners. Induction welding is a welding technique that relies on the application of an oscillating magnetic field on the joining interface, where a material called a magnetic susceptor generates heat by interacting with the applied magnetic field. In this work, susceptors relying on magnetic hysteresis losses made of polyetherimide (PEI) and nickel (Ni) particles are investigated with varying Ni concentration. The materials are mixed using an internal mixer and pressed to form films approximately 500μm thick. To characterize the heating rates of the susceptor materials, samples are placed on an induction coil – a water-cooled copper tube in which AC current (frequency 388kHz), generates an alternating magnetic field – and the temperature evolution is measured using a thermal camera. An increasing concentration of Ni particles results in increased heating rate and maximum temperature reached by the samples. The temperature-time experimental curves are compared with theoretical heating curves to verify if the model can be used to predict the temperature evolution at the joining interface during a welding process.","PeriodicalId":49577,"journal":{"name":"SAMPE Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135387964","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Compression Molding of Hybrid Continuous and Discontinuous Fiber Reinforced Thermoplastics for Enhancing Strength Characteristics 连续和间断纤维增强复合热塑性塑料的压缩成型研究

4区材料科学

SAMPE Journal Pub Date : 2023-09-01 DOI: 10.33599/sj.v59no5.03

Eduardo Barocio, Martin Eichenhofer, Jordan Kalman, Ludvik M. Fjeld, Joseph Kirchhoff, Garam Kim, R. Byron Pipes

{"title":"Compression Molding of Hybrid Continuous and Discontinuous Fiber Reinforced Thermoplastics for Enhancing Strength Characteristics","authors":"Eduardo Barocio, Martin Eichenhofer, Jordan Kalman, Ludvik M. Fjeld, Joseph Kirchhoff, Garam Kim, R. Byron Pipes","doi":"10.33599/sj.v59no5.03","DOIUrl":"https://doi.org/10.33599/sj.v59no5.03","url":null,"abstract":"Compression molding with long discontinuous fiber-reinforced thermoplastics enables replacing traditionally machined metallic components with geometrical complexity and with reductions in weight and potential enhancements in structural characteristics like durability, fatigue, and serviceability. Fiber length is critical in fiber-reinforced composites. While long continuous fibers limit the geometrical complexity that can be fabricated but provide exceptional mechanical properties, discontinuous fibers provide manufacturing flexibility but with a penalty in strength. This work demonstrates enhancement in strength and reduction in strength variability achieved by compression molding of long discontinuous fiber platelets and continuous fiber preforms. This approach was demonstrated for an overhead bin pin bracket geometry. Continuous fiber preforms were manufactured with 60% by volume of carbon fiber-reinforced Poly Ether Ketone Ketone (PEKK) using the 9T Labs continuous fiber Additive Fusion Technology (AFT). Similarly, fiber platelets with 60% by volume of carbon fiber reinforced PEKK were utilized. Continuous fiber preforms were designed considering both the concurrent flow of continuous and discontinuous fibers with the desired mesostructure of continuous and discontinuous fibers. The results presented in this work showed an increase of 99.6% in the load at the onset of damage by reinforcing the pin bracket with about 17% by weight of continuous fiber preforms. Similarly, the coefficient of variance of the load at the onset of failure decreased by 46%. Finally, reinforcing the pin bracket with continuous fiber preforms not only enhanced the strength characteristics but also decreased the variability in strength characteristics.","PeriodicalId":49577,"journal":{"name":"SAMPE Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135387728","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Mountain Bike Frame Innovation Using Thermplastic Composites - A Case Study 使用热塑性复合材料的山地车车架创新-一个案例研究

4区材料科学

SAMPE Journal Pub Date : 2023-09-01 DOI: 10.33599/sj.v59no5.04

Matt Giaraffa, D. DeWayne Howell

{"title":"Mountain Bike Frame Innovation Using Thermplastic Composites - A Case Study","authors":"Matt Giaraffa, D. DeWayne Howell","doi":"10.33599/sj.v59no5.04","DOIUrl":"https://doi.org/10.33599/sj.v59no5.04","url":null,"abstract":"For over 20 years the bike industry has been using composite materials to make mountain bike frames and other components, becoming the default high end material in the past 5-10 years. Thermoset based carbon fiber composites have traditionally led the way, but recently the next generation technology of thermoplastic infused carbon fiber composites have entered the market as recyclability, impact toughness, and vibration damping become more important. In particular, a new class of mountain bike frames has hit the trails as produced by Revved Industries for their in-house brand, Guerrilla Gravity. Increased impact toughness and vibration damping of thermoplastic composites offer attractive performance advantages that are ideal for applications such as mountain bike frames and components. Several thermoplastic composite material options were investigated and PA6/carbon fiber produced by Toray Advanced Composites was selected. A significant breakthrough in thermoplastic composite part forming, co-molding, and fusing has led to a durable and robust design that sets thermoplastic frames apart from their thermoset counterparts. This paper will review the material selection, design and analysis, fabrication, and testing of a mountain bike frame that has proven itself in the market today.","PeriodicalId":49577,"journal":{"name":"SAMPE Journal","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135387961","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0