Abstract
Abstract The viability of using induction heating to facilitate the wrinkle-free forming of multi-axial pre-consolidated advanced thermoplastic composites over complex geometries is explored. The research focuses on the use of tin as a medium to both heat and lubricate the forming laminate. Initial tests demonstrate the viability of the fundamental ideas of the process; induction heating is used to melt the tin sheet, which is then shown to melt the matrix phase of carbon-nylon composite laminates when stacked in a hybrid composite/tin layup. A novel low-cost reconfigurable multi-step forming tool is used to demonstrate how most of the tin can be squeezed out of the layup prior to consolidation. The multi-step tool can be augmented with segmented tooling to rapidly manufacture composite parts of high geometric complexity. In this investigation, a 'ripple' geometry containing three 'cavities' is used to demonstrate the technique. Tests demonstrated that at least three sheets of inter-laminar tin can be simultaneously melted using the induction heating system. Initial results indicate complex geometries can be formed with minimal wrinkling while removing interlaminar tin.
Highlights
If the inherent difficulties in manufacturing with advanced thermo plastic composites can be overcome, they offer a route to rapid production of high performance structural components
Rapid thermo-forming of advanced thermoplastic composite laminates [1,2,3,4,5,6,7,8,9,10,11,12,13,14,15] is of particular interest in the automotive in dustry due to the changing economics caused by legislative pressure to reduce emissions and improve recyclability [16]
Pre-consolidated sheets were made from carbon fibre – nylon com posite consisting of four plies of TenCate Cetex® TC910 Nylon 6 UD tape [40] in a [0◦/90◦/90◦/0◦] layup, initially bonded together using ultra sonic spot welding before being fully consolidated using a pressure of 5.9 bar at 270 ◦C
Summary
If the inherent difficulties in manufacturing with advanced thermo plastic composites can be overcome, they offer a route to rapid production of high performance (light-weight, tough, corrosion resistant, recyclable) structural components. Attempts to stamp form such a complex multi-cavity shape in one vertical forming step using two rigid tools could result in tearing of the blank, due to the large draw-in displace ments and high friction generated shear stresses between the composite blank and the tool. It is important to emphasise that the focus of this paper is on establishing the novel process itself and giving an initial assessment of its general effectiveness and viability In this case, there were many complex technological challenges involved in achieving a working process while operating under a time limit enforced by equipment rental – especially in simultaneously incorporating in duction heating, molten metal processing and multi-step forming in a composite forming process. Detailed mechanical, optical and radiographic characterisation of the formed parts is left to a follow-on paper
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