Evaluation of a Thermal Consolidation Process for the Production of Enhanced Technical Fabrics

Angelos Evangelou,Loukas Koutsokeras,Michalis Georgallas,Stylianos Yiatros,Charalabos Doumanidis,Orestes Marangos,Vassilis Drakonakis,Ernestos Sarris,Georgios Constantinides,Katerina Loizou

doi:10.3390/machines9080143

Angelos Evangelou, Loukas Koutsokeras + Show 8 more

Open Access

https://doi.org/10.3390/machines9080143

Copy DOI

Abstract

Fiber reinforced composites are increasingly used in high value applications. A novel technology (NanoWeld®) enhancing the structural integrity of the interlayer has demonstrated promising results; however, manufacturing issues related to scalability need to be overcome. The developed technology relies on consolidating thermoplastic nanofiber nonwoven veils onto technical dry fabrics through roll-to-roll ultrasonic welding. The enhanced technical dry fabrics can be further processed as any other technical fabrics for the composites industry. An alternative solution for consolidation is proposed here, based on a thermo-compressive approach to address the scalability issue. A finite element model has been employed to simulate the operating conditions and provide information for optimization of the process. Its results demonstrate that consolidation is achieved rapidly, indicating that the production rate could be accelerated. The quality of enhanced technical dry fabrics produced using the proposed consolidation assembly has been evaluated using scanning electron microscopy as well as mechanical testing of fiber reinforced composites. The mechanical response of such manufactured composites has been compared against benchmark NanoWeld® composites, demonstrating superior performance.

Highlights

Over the years, use of fiber reinforced polymers (FRPs) in primary structures of major load-bearing applications has increased
In this way it was ensured that the accurate magnitude was measured experimentally of the temperature that was transferred from the aluminum platen to the material system below
This magnitude presents periodicity but for the simulation this magnitude was applied for only one cycle, because temperature equalizes with the boundary condition applied over the first cycle

Summary

Introduction

Use of fiber reinforced polymers (FRPs) in primary structures of major load-bearing applications has increased. In conventional FRPs, the interlaminar region consists solely of thermosetting resin which lacks strength and toughness. Several attempts have been made towards the latter, including, for example: (i) dispersion of nanoparticles in the polymeric matrix of FRPs [2,3]; (ii) dispersion of nanoparticles in the sizing agent of the fibers; (iii) direct growth of nano-entities on the surface of the fibers [4,5]; (iv) spray coating of the fibers [6]; (v) nanocomposite films introduced at the interlayer [7]; (vi) porous nanoparticle preforms introduced at the interlayer [8] and nano-enabled polymer fiber veils as interlayer reinforcement [9]

Methods

Results

Conclusion