Experimental process characterisation for high-volume compression moulding of hybrid-architecture composites

Abstract

Compression moulding of woven fabric prepreg and sheet moulding compound (SMC) in a single-shot process combines the superior mechanical properties of continuous fibre composites and the high design flexibility of discontinuous fibre composites. This experimental study presents insights into the moulding characteristics of prepreg and SMC and explores the interaction between these two materials during manufacturing of hybrid-architecture composites. All tests were performed under typical compression moulding conditions using a squeeze flow testing rig. The response of each material was interpreted through proposed material models applied to the data acquired from single architecture tests. Critical interaction mechanisms were identified from hybrid architecture tests, alongside some additional deformation mechanisms, such as high level of in-plane fibre tow deformation not observed in single-architecture tests. Novel experimental methods were also introduced to quantify the change in meso-scale fibre architecture in the prepreg induced by the flow of SMC. The outcomes of this study not only shed light on the essential interaction mechanisms of hybrid-architecture composites but also provide valuable insights into deformation mechanisms not apparent in isolated material studies. Ultimately, these findings will facilitate the future development of a numerical simulation model for hybrid moulding processes.