Filament Winding Process Research Articles

Axial Impact Response of Carbon Fiber-Reinforced Polymer Structures in High-Speed Trains Based on Filament Winding Process.

The continuous increase in the operating speed of rail vehicles demands higher requirements for passive safety protection and lightweight design. This paper focuses on an energy-absorbing component (circular tubes) at the end of a train. Thin-walled carbon fiber-reinforced polymer (CFRP) tubes were prepared using the filament winding process. Through a combination of sled impact tests and finite element simulations, the effects of a chamfered trigger (Tube I) and embedded trigger (Tube II) on the impact response and crashworthiness of the structure were investigated. The results showed that both triggering methods led to the progressive end failure of the tubes. Tube I exhibited a mean crush force (MCF) of 891.89 kN and specific energy absorption (SEA) of 38.69 kJ/kg. In comparison, the MCF and SEA of Tube II decreased by 21.2% and 21.9%, respectively. The reason for this reduction is that the presence of the embedded trigger in Tube II restricts the expansion of the inner plies (plies 4 to 6), thereby affecting the overall energy absorption mechanism. Based on the validated finite element model, a modeling strategy study was conducted, including the failure parameters (DFAILT/DFAILC), the friction coefficient, and the interfacial strength. It was found that the prediction results are significantly influenced by modeling methods. Specifically, as the interfacial strength decreases, the tube wall is more prone to circumferential cracking or overall buckling under axial impact.

Hygroscopic and hydrothermal aging behaviors and performance deterioration mechanisms of jute yarn wound composites

The gyratory jute yarn wound composites (JYWCs) manufactured by the filament winding process show significant potential as eco-friendly alternatives to plastic pipes commonly used in outdoor settings. Ensuring the long-term service performance and durability of the JYWCs in hot and humid environments becomes critical. This study investigated the hygroscopic and hydrothermal aging behaviors of the JYWCs to elucidate their performance deterioration mechanisms. Compared with hygroscopic aging, long-term hydrothermal aging posed a more serious threat to the overall performance of the JYWCs. The jute yarns in the JYWCs experienced swelling, shrinkage, and degradation due to hygroscopic and hydrothermal aging, leading to a 47.4 % and 161.5 % increase in the void volume fraction of the JYWCs, respectively. The deterioration in the mechanical properties of the JYWCs was attributed to the attenuation of jute yarn properties, debonding of the fiber-resin matrix interface, and an increase in voids within the composites. Improving the manufacturing process to minimize voids in the JYWCs and control the pathways for moisture absorption is a highly effective strategy to enhance their long-term performance and durability.

Preparation and Application of a Novel Liquid Oxygen-Compatible Epoxy Resin of Fluorinated Glycidyl Amine with Low Viscosity

A liquid oxygen-compatible epoxy resin of fluorinated glycidyl amine (TFEPA) with a low viscosity of 260 mPa·s in a wide range of temperatures, from room temperature to 150 °C, was synthesized and used to decrease the viscosity of phosphorus-containing bisphenol F epoxy resins. And the forming process and application performances of this resin system and its composite were investigated. The viscosity of the bisphenol F resin was decreased from 4925 to 749 mPa·s at 45 °C by mixing with 10 wt.% TFEPA, which was enough for the filament winding process. Moreover, the processing temperature and time windows were increased by 73% and 186%, respectively. After crosslinking, the liquid oxygen compatibility was preserved, and its tensile strength, elastic modulus, and breaking elongation at −196 °C were 133.31 MPa, 6.59 GPa, and 2.36%, respectively, which were similar to those without TFEPA. And the flexural strength and modulus were 276.14 MPa and 7.29 GPa, respectively, increasing by 21.73% in strain energy at flexural breaking, indicating an enhanced toughness derived from TFEPA. Based on this resin system, the flexural strength and toughness of its composite at −196 °C were 862.73 MPa and 6.88 MJ/m3, respectively, increasing by 4.46% and 10.79%, respectively.

The Effects of Laser-Assisted Winding Process Parameters on the Tensile Properties of Carbon Fiber/Polyphenylene Sulfide Composites.

Currently, there is limited research on the in situ forming process of thermoplastic prepreg tape winding, and the unclear impact of process parameters on mechanical properties during manufacturing is becoming increasingly prominent. The study aimed to investigate the influence of process parameters on the mechanical properties of thermoplastic composite materials (CFRP) using laser-assisted CF/PPS winding forming technology. The melting point and decomposition temperature of CF/PPS materials were determined using DSC and TGA instruments, and based on the operating parameters of the laser-assisted winding equipment, the process parameter range for this fabrication technology was designed. A numerical model for the temperature of laser-heated CF/PPS prepreg was established, and based on the filament winding process setup, the heating temperature and tensile strength were simulated and tested. The effects of process parameters on the heating temperature of the prepreg and the tensile strength of NOL rings were then analyzed. The non-dominated sorting genetic algorithm (NSGA-II) was employed to globally optimize the process parameters, aiming to maximize winding rate and tensile strength. The results indicated that core mold temperature, winding rate, laser power, and their interactions significantly affected mechanical properties. The optimal settings were 90 °C, 418.6 mm/s, and 525 W, achieving a maximum tensile strength of 2571.51 MPa. This study provides valuable insights into enhancing the forming efficiency of CF/PPS-reinforced high-performance engineering thermoplastic composites.

Design, Simulation, and Fabrication of Composite Lattice Orthoses with Enhanced Structural Performance

Abstract Orthoses play a critical role in rehabilitation by providing fracture stabilization, external load protection, and deformity correction. Traditional methods of orthotic manufacturing often result in reduced breathability leading to potential skin problems, and increased bulkiness and weight due to material and processing limitations. Method: This study aims to enhance breathability and structural performance of orthoses through the utilization of a fiber-reinforced composite lattice design fabricated using a Coreless Filament Winding (CFW) process. An arm brace was designed and manufactured, which incorporates four modules made of fiberglass/polystyrene composite lattices assembled together using adjustable thermoplastic connectors. To simulate the structural performance, a Finite Element Model (FEM) was constructed with careful consideration of the interactions between the connectors and the lattice modules, and this was subsequently validated through experiment. Results: In comparison to a benchmark brace made of Polylactic Acid (PLA) lattice, the composite brace exhibits a significant reduction in thickness (60%) and weight (44%) while maintaining equivalent structural performance. The validation test indicates the FEM's reliability in predicting structural stiffness and strength, with the predicted peak loading being slightly conservative (5%) compared to experimental results. Conclusion: Composite lattice structures represent a significant advancement in the design of breathable, lightweight, and high-strength orthoses. Moreover, the developed FEM serves as a valuable tool for accurately predicting structural performance and optimizing orthotic design under varying loading conditions.

Using Light Polarization to Identify Fiber Orientation in Carbon Fiber Components: Metrological Analysis.

In this work, a method for measuring tow angles in carbon fiber components, based on the use of a polarized camera, is analyzed from a metrological point of view. Carbon fibers alter the direction of the reflected light's electrical field, so that in each point of the surface of a composite piece, the angle of polarization of reflected light matches the fiber orientation. A statistical analysis of the angle of linear polarization (AoLP) in each pixel of each examined area allows to evaluate the average winding angle. An evaluation of the measurement uncertainty of the method on a cylinder obtained by a filament winding process is carried out, and the result appears adequate for the study of the distribution of angles along the surface of the piece, in order to optimize the process.

Manufacturing of hexagonal cross-section thermoplastic matrix composite parts with automatic filament winding system

Thermoplastic filament winding is a flexible manufacturing method typically used in the production of cylindrical composite structures, allowing for in-situ consolidation without the need for a second consolidation step. The objective of this study is to produce non-cylindrical geometries, typically manufactured using thermoset matrix composites according to the literature, using the thermoplastic filament winding process. For this purpose, glass fiber (GF) reinforced polypropylene (PP) prepreg tapes were used to produce hexagonal cross-section thermoplastic composite parts. The critical process parameters; hot-air heater nozzle temperature, compression roller pressure, the linear speed of mandrel rotation, and corner radius of the mandrel, were determined using the Taguchi experimental design method. The interlaminar shear strength (ILSS) and maximum compressive strength (σmax) values were obtained as 211 MPa and 49.40 MPa as maximum, respectively. ANOVA analysis showed that the corner radius had the most significant impact on ILSS, while mandrel rotation speed and temperature were critical for σmax.

An experimental investigation into crashworthiness of filament wound intra-yarn hybrid glass/jute epoxy composites tubes under quasi-static axial and lateral compression

The increasing demand for sustainable materials in the automotive industry has driven the research towards exploration of natural fiber composites for crash structures. This study investigates the quasi-static axial and lateral crushing behavior of hybrid glass/jute fiber epoxy tubes. Intra-yarn hybrid mixing ratios of jute and glass fibers were tested to evaluate the feasibility of using natural fibers as eco-friendly alternatives to traditional synthetic composites. A total of five different configurations were fabricated using filament winding process. The experimental results were analyzed for collapsing behavior, failure modes, and energy absorption characteristics. The hybrid epoxy tubes revealed fiber-matrix fracturing, local buckling, and delamination as three primary failure modes under crushing tests. The hybrid configuration with 25 % jute fiber and 75 % glass fiber demonstrated optimal crashworthiness performance, achieving the highest specific energy absorption (SEA) values of 15.85 J/g under axial loading and 2.96 J/g under lateral loading. The configurations with higher jute content of 50 % and 75 %, showed decreasing SEA and crush force efficiency (CFE) values, with brittle fracturing and delamination as dominant failure modes, indicating a trade-off between weight and energy absorption efficiency. The neat glass fiber configuration maintained nearly consistent CFE values of 0.55 and 0.56, between axial and lateral loadings respectively, demonstrating isotropic behavior in energy absorption. Conversely, the neat jute fiber configuration improved SEA to 12.14 J/g under axial loading but exhibited significant limitations under lateral loading, with SEA decreasing to 0.69 J/g. Visual examination of crushed samples highlighted local buckling in GF configurations and brittle fracturing in hybrid and neat jute fiber configurations. The scanning electron microscope (SEM) analysis provided detailed insights into the microstructural characteristics and failure mechanisms, highlighting the inter-laminar debonding between the jute and glass fibers in hybrid configuration. By evaluating the combined effects of hybridization and loading conditions, the present study contributes to developing eco-friendly and efficient materials for automotive safety, aligning with industry sustainability goals.

Vibration analysis of anisogrid composite lattice sandwich truncated conical shells: Theoretical and experimental approaches

Drawing upon both theoretical and experimental methodologies, this study investigates the vibrational characteristics of lattice sandwich truncated conical shells featuring composite ribs made of carbon and E-glass fibers. Toward this aim, the equations of motion along with the corresponding boundary conditions of such sandwich shells are derived using classical Donnell’s shell theory and the smeared stiffness technique. Subsequently, the governing equations are solved to obtain a closed-form expression for natural frequencies employing the Galerkin method. In addition, ABAQUS simulations are presented to study the vibration behavior of single-skin and three-skin conical shells. To validate the theoretical methods, the specimens of three-layer sandwich conical shells were fabricated from two Kevlar fabric laminates and a composite lattice core with hexagonal cells using a manual filament winding process. The composite ribs consist of carbon and E-glass fibers with a ratio of 3:1. Finally, experimental modal tests were conducted to extract natural frequencies and mode shapes by measuring frequency responses at 40 points over a duration of 60 s using a laser vibrometer. A strong correspondence is observed between the theoretical outcomes (utilizing the Galerkin and FE methods) and the experimental findings (with a maximum discrepancy of approximately 16% for the initial four mode shapes). Findings indicate that the excellent performance of the composite lattice core in vibration behavior, which can increase approximately 19% and 16% the natural frequencies corresponding to the first and second mode shapes, respectively.

Cross-Scale Industrial Manufacturing of Multifunctional Glass Fiber/Epoxy Composite Tubes via a Purposely Modified Filament Winding Production Line.

In the present research work is demonstrated a cross-scale manufacturing approach for the production of multifunctional glass fiber reinforced polymer (GFRP) composite tubes with a purposely redesigned filament winding process. Up until now, limited studies have been reported towards the multiscale reinforcement direction of continuous fibers for the manufacturing of hierarchical composites at the industrial level. This study involved the development of two different multi-walled carbon nanotube (MWCNT) aqueous-based inks, which were employed for the modification of commercial glass fiber (GF) reinforcing tows via a bath coating unit in a pilot production line. The obtained multifunctional GFRP tubes presented a variety of characteristics in relation to their final mechanical, hydrothermal aging, electrical, thermal and thermoelectric properties. Results revealed that the two individual systems exhibited pronounced differences both in crushing behavior and durability performance. Interestingly, for lateral compression the MWCNT coatings comprising a polymeric dispersant minorly affected the mechanical response of the produced tubes. The crashworthiness indicators of the multifunctional tubes displayed a slight 5% variation to the respective reference values, combined with a more ductile behavior. Moreover, regarding the bulk electrical and thermal conductivity values, as well as the Seebeck coefficient factor, the corresponding tubes displayed a variance of 233% and 19% and an opposite semi-conducting sign denoting a p- and n-type character, respectively.

Characterization and modeling of an epoxy vitrimer based on disulfide exchange for wet filament winding applications

AbstractThe present paper investigates the suitability of a vitrimeric epoxy resin for processing in the wet filament winding (WFW) process to manufacture fiber‐reinforced polymers (FRP). Comprehensive material characterization of a commercially available epoxy and vitrimeric resin based on disulfide exchange is carried out, and the processing in WFW is evaluated by analyzing thermomechanical, rheological, thermochemical properties, and chemical shrinkage. The direct comparison of a vitrimer and an established epoxy resin permits an indication of the processability and necessary adjustments in WFW. Based on the implications of modeling, we demonstrate the processing of the vitrimeric resin in the WFW process by increasing the resin bath temperatures. The vitrimer's and conventional resin's elastic modulus development and compression behavior were similar, highlighting the vitrimeric resin's potential. Further, the results confirm that established characterization and modeling routines can be transferred to vitrimeric resins and, therefore, path the way toward advanced process simulation of vitrimeric resin's processing. For this, the present publication gives essential advice for setting up testing schedules for characterizing epoxy vitrimers' processing behavior and their appropriate modeling. The present work underlines the potential of applying commercially available dynamic hardeners to manufacture recyclable and malleable FRP in established processes.Highlights Material characterization and modeling of wet filament winding process. Wet filament winding of epoxy vitrimers. Thermomechanical and chemical shrinkage characterization of epoxy vitrimers. Rheological and kinetic modeling of epoxy vitrimer.

Flexural behavior of carbon/epoxy nanocomposite pipes with interleaved structure

The filament winding process used in this study mainly produces pipe-shaped structures. In this structure, there is an intersection of fiber bundles, which makes the fiber bundles overlapping with other fiber bundles wavy. In that area, the concentration of stress and deformation appears. Therefore, halloysite nanotubes were applied among nanoparticles to supplement this through the study. In the utilization of nanoparticles, the control of agglomeration phenomena and the ease of dispersion are pivotal factors. In consideration of this, general halloysite nanotubes were heat-treated at 1000∘C to produce amorphous halloysite nanotubes to reduce the surface energy of particles, making it easier to control agglomeration phenomena and the ease of dispersion, and it was intended to supplement and improve mechanical properties in local applications through interleaved structure design. In this study, each stacked structure was analyzed through an axial pipe bending test. The fracture pattern for each structure was observed through an optical microscope. As a result, A3 reinforced with A-HNT for all layers had the highest load value (4207N), and the flexural strength was also measured high accordingly. It shows a small degree of fracture compared to other structures. Following that, E2A1, whose innermost layer was reinforced with A-HNT, had the second-highest load value (3864N), and accordingly, the second-highest flexural strength was measured. The observed surface of the pipe was the outermost layer (E), and it was observed that the degree of fracture was more advanced than that of A3.

Influence of Resin Viscosity on Physical Properties of a Composite Shell Wound on a Low Density Material Mandrel

This study is made to improve the structural performance of composite shells/ vessels meant for aerospace vehicles. The effect of resin viscosity on the physical properties of carbon/ epoxy composite shell wound on polyurethane (PU) foam-based mandrel is studied and presented in this paper. Cylindrical shells were manufactured through the filament winding process at different resin viscosities. The physical properties of the composite shell are found to be improved significantly with a reduction in resin viscosity. Resin pick-up in impregnated fibers is found to be lower by 4.5 %, whereas mass and thickness of the shells are recorded to be lower by 3 % and 5.4 % respectively at resin viscosity range of 600 -760 mPa.s compared to the viscosity range of 1380 – 2080 mPa.s. Fiber volume fraction and density of composite shell are found to be higher by 6.3 % and 2.8 % at the same resin viscosity range. This trend reverses/stabilizes after further heating and corresponding lowered resin viscosity. Experiment and their result indicate an optimal viscosity range of 600 – 760 mPa.s. for filament winding of efficient carbon/ epoxy composite shell

Carbon nanotube composites fabricated through filament winding process for battery preheating application

AbstractCarbon nanotube (CNT) polymer composites have broad application prospects in thermal management as electrothermal heaters. Nevertheless, challenge remains in achieving high electrical conductivity for the composites due to the contradiction between CNTs and insulated polymers. To address this issue, herein, innovative use of interface strategy approach by constructing synergistic nanomaterial networks on carboxyl CNTs yarn winding composites for improving the interfacial adhesion and electrical performance. In the work, carboxyl CNTs yarn/CNTs‐graphene oxide (GO) polyvinyl alcohol (PVA) composites (C‐CY‐HP‐C) were proposed and manufactured via filament winding process. The as‐constructed C‐CY‐HP‐C demonstrated a remarkable interfacial shear strength of 2057.16 N mm−1, which was 53.59% higher than that of control CNTs yarn/PVA winding composites. In addition, the C‐CY‐HP‐C achieved an attractive electrical conductivity of 346.39 S cm−1 owing to the electronic transmission channels were formed. Notably, the superior electrical conductivity facilitated a rapid‐response of electrothermal performance for the C‐CY‐HP‐C. It reached a steady‐state temperature of 229.9°C within 10 s when the voltage was 1.2 V. Concurrently, it exhibited an impressive heating rate of 10.8°C min−1 at an ambient temperature of −20°C as the battery surface heater. These findings shed light on the development of technique for battery preheating system based on CNTs yarn/polymer composites.

Voids in type-IV composite pressure vessels manufactured by a dry filament-winding process

Type-IV high-pressure hydrogen-gas tanks for fuel-cell electric vehicles are made from carbon fiber-reinforced plastic. Their production involves wrapping a carbon-fiber-reinforced thermoset resin towpreg around a plastic liner to form a tank shape, followed by heating in an oven to cure the thermoset resin. The filament-winding process produces many voids in the tank that cause variations in quality and the product lifetime. In this study, the voids in the tank were classified according to their origin. A type-IV high-pressure hydrogen-gas tank with a burst pressure of 70 MPa was fabricated, and the voids produced in the tank were observed. The same filament-winding process was used to fabricate a plate and tank with a simple winding trajectory to identify the voids. The voids produced in the tank by the filament winding were categorized into six groups based on their location, cross-sectional shape, and size, showing the origin of the voids.

Design of Type-IV Composite Pressure Vessel Based on Comparative Analysis of Numerical Methods for Modeling Type-III Vessels

Compressed gas storage of hydrogen has emerged as the preferred choice for fuel cell vehicle manufacturers, as well as for various applications, like road transport and aviation. However, designers face increasing challenges in designing safe and efficient composite overwrapped pressure vessels (COPVs) for hydrogen storage. One challenge lies in the development of precise software programs that consider a multitude of factors associated with the filament winding process. These factors include layer thickness, stacking sequence, and the development of particularly robust models for the dome region. Another challenge is the formulation of predictive behavior and failure models to ensure that COPVs have optimal structural integrity. The present study offers an exploration of numerical methods used in modeling COPVs, aiming to enhance our understanding of their performance characteristics. The methods examined include finite element analysis in Abaqus, involving conventional shell element, continuum shell element, three-dimensional solid element, and homogenization techniques for multilayered composite pressure vessels. Through rigorous comparisons with type-III pressure vessels from the literature, the research highlights the most suitable choice for simulating COPVs and their practicality. Finally, we propose a new design for type-IV hydrogen composite pressure vessels using one explored method, paving the way for future developments in this critical field.

Design and manufacture of a Type V composite pressure vessel using automated fibre placement

Automated fibre placement (AFP) can improve composite pressure vessel design by enabling selective reinforcement and allowing a wider range of fibre orientations than the traditional filament winding process. This paper presents the development of an AFP Type V composite pressure vessel with a design working pressure of 4.22 MPa made using a novel collapsible mandrel. The design process is presented along with a thickness control strategy for the AFP parts using ply drops. The tank was manufactured, and the thickness was validated using 3D scanning. The masses of the AFP parts were also measured to within 2.23% of the predicted values. The finished tank was hydrostatically pressure tested to understand the leakage behaviour. Defects and difficulties encountered in this prototype are discussed and opportunities for future work and improvements have been identified.

Hybrid Aluminized Fiberglass Reinforced Composite Pipes: A Framework for Safety Use in Industries

Introduction: Polymer matrix composites have been utilized in various industries due to their low cost and good strength-to-weight ratios. AIM: This study aims to investigate the effectiveness of filament-wound fiber-reinforced polymer composite pipes. The focus is on aluminized fabric tubes, which are flexible and heat-resistant tubes made from a glass fabric and laminated with a layer of aluminum. AIM: This study aims to investigate the effectiveness of filament-wound fiber-reinforced polymer composite pipes. The focus is on aluminized fabric tubes, which are flexible and heat-resistant tubes made from a glass fabric and laminated with a layer of aluminum. Method: These tubes offer unique properties that make them suitable for various applications, especially in environments with high temperatures or exposure to radiant heat. Fiber Reinforced Plastic (FRP) pipes are highlighted for their lightweight, easy transportation, low maintenance, corrosion resistance, design flexibility, and anti-freezing performance. The study delves into the use of aluminized glass fiber for high-temperature applications, with a specific focus on enhancing high-temperature withstanding properties. Result: In addition, the present research also conducts tests to study the structural strength of normal glass fabric tubes and aluminized glass fabric tubes. The fabrication of composite pipes is achieved through a filament winding process with a zero-degree winding angle using a manually operated filament winding machine. Mechanical testing and Finite Element Analysis (FEA) simulations using ANSYS® are also performed to compare glass fiber-reinforced plastic pipes with hybrid aluminized fiber-reinforced plastic pipes. Conclusion: The application of aluminized glass fiber in both the internal and external layers of the pipes improves the pipe’s strength and ability to endure high temperatures.

A novel model for buckling of composite shell: Ring stiffened shell and stiffened shell with cutout under hydrostatic pressure

Focusing on buckling problem under hydrostatic pressure of ring stiffened shells and shells with stiffened cutout fabricated by filament winding process, a new form of equilibrium equations is given in this paper based on high-order shear deformation theory (HSDT). A novel theoretical model is proposed based on Messager's model of geometrical imperfection. The model contains both ring stiffened shell model (RSSM) and stiffened shell with cutout model (SSCM). In this model, changes in the shells' thickness z˜k(x,y),k=1,2,…,n are described using a Fourier series representation, which is included in HSDT stiffness matrix A, B, D, E, F, H. To evaluate the critical buckling pressure pcr, the model is applied and compared with the conventional stiffened cylindrical shell (SCS) model. The results demonstrate a significant reduction in error, ranging from 71.08% to 81.22%, when using the proposed model for shells stiffened by a ring stiffener in the middle, as compared to the SCS model. This highlights the enhanced accuracy provided by the proposed model. The results indicate that small stiffened cutouts in thin shells and large stiffened cutouts in moderately thick shells have relatively small influence on the critical buckling pressure. Conversely, the presence of a ring stiffener in the middle has a more pronounced effect.

On the winding pattern influence for filament wound cylinders under axial compression, torsion, and internal pressure loads

An intrinsic characteristic of components manufactured by the filament winding process is a winding pattern formation during the processing. This paper aims at unlocking and understanding how the winding pattern influences the mechanical behaviour of filament wound cylinders under different boundary conditions. To realize this, a series of finite element models followed by an original geometric approach to generate the pattern are herein developed. Four different patterns and six different winding angles are modelled. These are also modelled by varying the number of layers towards understanding whether there is a correlation between the pattern and the number of layers or not. Three loading cases are considered: axial compression, pure torsion, and internal pressure. Key results reveal that the more layers are stacked to the cylinder, the less impactful is the winding pattern to all loading cases herein investigated.