Induction melt thermoforming of advanced multi-axial thermoplastic composite laminates

Harrison, P. , Campbell, I., Guliyev, E., McLelland, B., Gomes, R., Curado-Correia, N., McGookin, E. and Mulvihill, D.M. (2020) Induction melt thermoforming of advanced multi-axial thermoplastic composite laminates. Journal of Manufacturing Processes, 60, pp. 673-683. (doi: 10.1016/j.jmapro.2020.10.026)

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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.

Item Type:Articles
Status:Published
Refereed:Yes
Glasgow Author(s) Enlighten ID:Mulvihill, Dr Daniel and Campbell, Iain and Harrison, Dr Philip and McGookin, Dr Euan
Authors: Harrison, P., Campbell, I., Guliyev, E., McLelland, B., Gomes, R., Curado-Correia, N., McGookin, E., and Mulvihill, D.M.
College/School:College of Science and Engineering > School of Engineering > Aerospace Sciences
College of Science and Engineering > School of Engineering > Systems Power and Energy
Journal Name:Journal of Manufacturing Processes
Publisher:Elsevier
ISSN:1526-6125
ISSN (Online):2212-4616
Published Online:17 November 2020
Copyright Holders:Copyright © 2020 The Authors
First Published:First published in Journal of Manufacturing Processes 60:673-683
Publisher Policy:Reproduced under a Creative Commons License

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Project CodeAward NoProject NamePrincipal InvestigatorFunder's NameFunder RefLead Dept
300979Multi-Step Thermoforming of Multi-Cavity, Multi-Axial Advanced Thermoplastic Composite PartsPhilip HarrisonEngineering and Physical Sciences Research Council (EPSRC)EP/P006701/1ENG - Systems Power & Energy
172865EPSRC DTP 16/17 and 17/18Tania GalabovaEngineering and Physical Sciences Research Council (EPSRC)EP/N509668/1Research and Innovation Services