Filament Winding Research Articles

Effect of temperature on flexural and interlaminar shear strength properties of carbon‐epoxy composites: Experiment and modeling

AbstractCarbon fiber composites are known for excellent specific mechanical properties at room temperature. It is important to model the effect of temperature on flexural strength and interlaminar shear strength (ILSS). In this study, T700 carbon fiber composites with two different epoxy resins (Epofine, LY556) were prepared using filament winding and named as TE and TL composites. The dynamic mechanical analysis (DMA) tests revealed Tg of 177 and 192°C for TE and TL composites, respectively. Three‐point bending (flexural) and short‐beam shear (ILSS) tests were performed at −20, 0, RT, 90, 105, 150, 170, and 200°C. It was observed that flexural strength and ILSS decreases linearly with increase in temperature. Fracture analysis of flexural samples revealed fiber breakage at −20°C and micro‐buckling at elevated temperature are dominant failure mechanisms. Fracture analysis of ILSS samples showed delamination with microcracking at −20°C and plastic deformation of matrix at elevated temperature. A new empirical model was proposed to predict the temperature dependent flexural strength and ILSS. With this model, variation of flexure strength and ILSS with temperature can be estimated from respective values at RT, Tg and storage modulus values from DMA, thus extensive experimentation at high temperatures can be avoided.Highlights Mechanical properties of filament wound composites are tested from −20 to 200°C. Flexural strength and ILSS linearly decreases with increase in temperature. Fiber breakage at −20°C and micro bucking at 200°C are dominant in flexure. Delamination at −20°C and plastic deformation at 200°C are dominant in ILSS. Analytical model for finding temperature dependent flexural strength and ILSS.

Long-span fiber composite truss made by coreless filament winding for large-scale satellite structural systems demonstrated on a planetary sunshade concept

Climate change necessitates exploring innovative geoengineering solutions to mitigate its effects—one such solution is deploying planetary sunshade satellites at Sun–Earth Lagrange point 1 to regulate solar radiation on Earth directly. However, such long-span space structures present unique technical challenges, particularly structural scalability, on-orbit manufacturing, and in-situ resource utilization. This paper proposes a structural concept for the sunshade’s foil support system and derives from that a component-level modular system for long-span fiber composite lightweight trusses using coreless filament winding. Within a laboratory-scale case study, the component scalability, as well as the manufacturing and material impacts, were experimentally investigated by bending deflection testing. Based on these experimental results, FE models of the proposed structural concept were calibrated to estimate the maximum displacement and mass of the foil support structure, while comparing the influences of foil edge length, orbital load case, and material selection.

Evolution of variable angle tow composite structures: Data analysis and relevance of the theme

Variable angle tow composites were developed to increase stiffness in notched laminates. Scientific advancements in manufacturing and fiber path optimization have since improved variable angle tow composites. This study uses bibliometric analysis to track the evolution of variable angle tow composites in the literature. Bibliometric analysis is a useful tool for measuring paper contributions and accurately assessing performance, aiding authors in the research process. This article presents a co-occurrence map of keyword frequency in research papers. Furthermore, an experimental section highlights manufacturing defects found in variable angle tow composites produced by filament winding, showing that manufacturing real structures in variable angle tow composites poses a significant challenge. Lastly, the perspectives of variable angle tow composite applications are discussed.

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

Effect of fiber tension on physical and mechanical properties of filament wound carbon/epoxy composite specimen

Effect of fiber tension on physical and mechanical properties of filament wound carbon/epoxy composite specimen

Towpreg manufacturing and characterization for filament winding application

AbstractIn the field of textile technology, this study centers on towpreg—an integral component utilized in production techniques like tape laying and filament winding. Here, fibers are pre‐coated with resin, typically epoxy but not exclusively. Notably, towpreg retains a partially cured state, maintaining tackiness throughout the processing stages. The ultimate quality of the product manufactured with this towpreg is highly dependent on this initial material. This research highlights the importance of considering various factors that impact product quality. While not exhaustive, a systematic analysis of diverse towpreg parameters, including tack, resin content, and width, is provided. The work encompasses findings, challenges, and insights derived from towpreg manufacturing, incorporating the investigation of various experimental methodologies. The study also evaluates methodologies for laminated coupon production with towpreg, assessing their applicability in characterizing filament‐wound components. Although the article seems like a review, the authors aim to give a clear and holistic picture in one work instead of spreading information across many articles.Highlights Techniques for the quantification of towpreg tack are presented. Resin content distribution along towpreg length is presented. Towpreg width variation was investigated, seen to be one of the major causes for the gaps and voids in a filament wound composite. Coupon‐level characterization of towpreg through filament winding approach is presented. Other filament winding parameters influencing the quality of the manufactured composite are discussed.

A Review on Composite Materials Reinforcing with Organic/ Natural Materials

The utilization of natural and fiber-reinforced polymer matrix composites as a sustainable solution in the industries. The composite consists of sugarcane bagasse and mesquite fibers. which offers a low-cost, environmentally friendly alternative with potential applications in various industries. epoxy resin known for its cost-effectiveness and resilience, serves as the matrix material. Types of fabrication methods are Vacuum Bag Molding, Hand Lay-Up, Filament Winding, and Hydraulic compression molding from the literature we collected Hydraulic compression molding technique with varying fiber orientations (uniaxial, biaxial, and triaxial) is selected for its versatility and reduced material waste. The study involved alkaline, potassium permanganate, and potassium dichromate treatments. The overall study concludes the promising potential of using bagasse and mesquite fibers as sustainable alternatives for reinforcement in epoxy resin composites, offering a viable solution for valorizing agricultural waste and promoting environmentally conscious manufacturing practices. Chemical treatments and fiber processing play a crucial role in enhancing the properties of the fibers, making them suitable for composite applications.

Design, Manufacture, and Cryogenic Testing of a Linerless Composite Tank for Liquid Hydrogen

This paper describes design, manufacture, and testing of a linerless composite vessel for liquid hydrogen, having 0.3 m diameter and 0.9 m length. The vessel consists of a composite cylinder manufactured by wet filament winding of thin-ply composite bands, bonded to titanium end caps produced by additive manufacturing. The aim was to demonstrate the linerless design concept with a thin-ply composite for the cylinder. The investigation is limited to the internal pressure vessel, while real cryogenic tanks also involve an outer vessel containing vacuum for thermal insulation. Thermal stresses dominate during normal operation (4 bar) and the layup was selected for equal hoop strains in the composite cylinder and end caps during filling with liquid hydrogen. Two vessels were tested in 20 cycles, by filling and emptying with liquid nitrogen to 4 bar, without signs of damage or leakage. Subsequently, one vessel was tested until burst at almost 30 bar.

Complex design and analysis of filament wound composite pressure vessels using data driven evolutionary algorithms

The typical composite pressure vessel manufactured by means of filament winding consists of three elementary construction parts, that is, cylindrical part, end dome and the junction between its cylindrical part and the end dome which are subject of this article. The pressure vessel may fail in each of these three parts. Therefore, all of them must be considered during the design process. This study shows the possible way how to design an optimal pressure vessel related to chosen parameters (which can be mass of the pressure vessel, depth of the end dome, magnitude of internal pressure etc.), so that it does not fail in any construction parts. Any decision, whether the pressure vessel comply or not in studied places, is based on Hoffman's failure index analysis. The finding of an optimal solution requires performing a multi-objective optimization task, which was solved here using data-driven evolutionary algorithms. From the input data, which were generated through analytical approaches, surrogate models were created using the Evolutionary Deep Neural Nets (EvoDN2). These surrogate models were further used as an input to the optimization module which is based upon Constrained Reference Vector Evolutionary Algorithm (cRVEA). The results show that the pressure vessel designed in this way comply in each analyzed location. Moreover, it also finds the most stressed location, which can be useful for the designers.

Development of Fire Resistant Composite Material Using Fire Retardant Filler for Electrical Application

Safety is paramount across diverse sectors, with a growing emphasis on dependability. Preventing fires in electrical contexts and employing fire-resistant techniques using additives have become crucial. This involves the development of composite materials, typically incorporating substances like Alumina Rehydrate (ATH), metal hydroxides, or specialized additives such as epoxies, polyester, or polyurethane resins within polymer matrices. These formulations include fire-retardant fillers, underscoring their significance in enhancing safety and reliability. Increasing the fire resistance of the composite can be achieved through various methods such as delaying ignition, reducing flame spread, mitigating smoke emissions when exposed to high temperatures, and employing fire-resistant compounds to quench potential electrical arcs, especially in electrical applications where combustible materials pose significant hazards. These items consist of electrical casings, wire pathways, insulation, and other crucial components for ensuring fire safety within various systems. These components are chosen based on their electrical characteristics, strength, and the necessity for fire resistance, all of which contribute to achieving a harmonious balance. Careful consideration is given to adhesive matrices during the selection and optimization process as part of the development procedure. Advanced manufacturing methods such as Compression Melding, Resin Transfer Melding, or filament winding are utilized to produce composite components with standardized properties, enhancing overall efficiency.

Cygnet Texkimp Supplies Filament Winding Cell to TWI

Cygnet Texkimp Supplies Filament Winding Cell to TWI

Cylindrical single-wall and double-wall structures with or without internal water subjected to underwater shock loading

A series of experimental studies were conducted for cylindrical structures subjected to underwater shock loading to understand their dynamic responses and failure characteristics. All tests were performed inside an anechoic water tank. The submerged test cylinders were freely suspended, and an underwater shock loading was generated by the Compressed Air Shock Pipe Underwater Release (CASPUR) system. Cylinders were made of two different materials. The first group of cylinders was fabricated from carbon fiber and resin using the filament winding technique. The winding angles were ± 45° resulting in the same properties along axial and hoop directions. The second group of cylinders was constructed using a 3-D printer with polylactic acid (PLA) material. The 3-D printed cylinders had an orthotropic material property with different values in the axial and hoop directions. Both single-wall and double-wall cylindrical structures were tested. The latter consisted of two concentric cylinders of different diameters with uniform spacing between them. In addition, within the single-wall cylinders and the annuli of double-wall cylinders, the water fill was varied at 0%, 50%, or 100%. Pressure and strain gages were used to measure the shock pressure and deformation of the cylinders. The number of cylinders such as single-wall or double-wall and the internal water resulted in significant effects on the measured dynamic response (i.e., strain gage response) as well as the failure loading and failure characteristics including major failure locations. Internal water reduced the strain on the cylinders and made them withstand greater shock loading for both single-wall and double-wall cylinders.

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.

Acoustic emission detection of filament wound CFRP composite structure damage based on Mel spectrogram and deep learning

This paper investigates the hoop tensile mechanical properties, damage mode classification, and damage evolution process of the filament wound CFRP composite structure with different winding angles by acoustic emission and deep learning. Firstly, a clear correspondence between damage modes and peak frequency ranges is established by using k-means clustering results and eight frequency band ranges obtained by wavelet packet transform. On this basis, three damage modes are characterized according to the energy content of different frequency bands. Subsequently, the trained Mel spectrum-CNN classification model is used to identify damage modes and analyze the damage evolution process. The results show that the hoop tensile strength of the filament wound CFRP composite structure with ±55° is higher than that with ±35°. The primary damage modes during the tensile process are matrix cracking and fiber/matrix debonding. The Mel spectrogram-based damage identification method can effectively classify damage modes. In addition, the combination of acoustic emission and deep learning shows significant potential for damage identification and monitoring.

Stress and Deformation Analysis of Prestressed Wound Composite Components with an Arch-Shaped Metal Liner.

The stress distribution in prestressed filament wound components plays a crucial role in determining the quality of these components during their operational lifespan. This article proposes a physical model to analyze the stress and deformation of prestressed wound composite components with arch-shaped sections. Drawing upon the principles of beam theory, we delve into the analysis of prestressed wound components with metal liners featuring arch-shaped sections. Our investigation revealed a noteworthy phenomenon termed the "additional bending moment effect" within prestressed wound components with arch-shaped sections. Furthermore, this study establishes a relationship between this additional bending moment and the external pressure. In addition, a 3D finite element (FE) model for prestressed wound components with arch-shaped sections incorporating metal liners was developed. The model's accuracy was validated through a comparison with prestressed wound experiments, showcasing an error margin of less than 2%. In comparison with prestressed wound components with circular cross-sections under identical load and dimensional parameters, it was observed that prestressed wound components with arch-shaped sections exhibit stress distributions in the arc segments akin to their circular counterparts, with differences not exceeding 5%. Notably, when the ratio of the straight segment length to the inner diameter of the arc segment inner is less than 4, the deformation on the symmetric plane of the arc segment in an arch-shaped component can be effectively considered as the summation of deformations in equivalent-sized arc and straight segments under identical loading conditions. This yields an equivalent physical model and a streamlined analysis and design methodology for describing the deformation characteristics of prestressed wound components with arch-shaped sections.

Morphological analysis of as-manufactured filament wound composite cylinders using contact and non-contact inspection methods

Filament winding is a versatile technique for producing pressure vessels throughout the deposition of continuous fiber filaments on a rotating mandrel under determined conditions. Considering the relative safety requirements, these structures are expected to demonstrate high load carrying capacity to ensure the proper storage and transportation of pressurized fuels. Therefore, the quality of the manufactured product and the identification of defects, both structural and morphological, is essential. In the present work, measurements have been carried out in as-manufactured helicoidally filament wound cylinders, made of carbon fiber reinforced polymer, for identifying their morphological characteristics and the presence of variations of the winding angle and gaps or voids. A contact-based ultrasound system is employed to measure the wall thickness and to evaluate the existence of gaps between the layers through the thickness. Furthermore, a non-contact vision-based system is employed to scan and measure the variability of the winding angle. These techniques were applied to 2 identically fabricated filament wound products to identify the repeatability of the manufacturing process as well. The results revealed a deviation between the designed and manufactured product in terms of wall thickness and the actual filament winding angle and a strong variation of both through the various zones of interest through the length and the circumference.

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.

Enhancing Epoxy Composite Performance with Carbon Nanofillers: A Solution for Moisture Resistance and Extended Durability in Wind Turbine Blade Structures.

The increasing prominence of glass-fibre-reinforced plastics (GFRPs) in the wind energy industry, due to their exceptional combination of strength, low weight, and resistance to corrosion, makes them an ideal candidate for enhancing the performance and durability of wind turbine blades. The unique properties of GFRPs not only contribute to reduced energy costs through improved aerodynamic efficiency but also extend the operational lifespan of wind turbines. By modifying the epoxy resin with carbon nanofillers, an even higher degree of performance can be achieved. In this work, graphene nanoplatelet (GNP)-enhanced GFRPs are produced through industrial methods (filament winding) and coupons are extracted and tested for their mechanical performance after harsh environmental aging in high temperature and moisture. GNPs enhance the in-plane shear strength of GFRP by 200%, while reducing their water uptake by as much as 40%.