Rodriguez-Lence et al 2019a - Revision history

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Scipediacontent: Scipediacontent moved page Draft Content 917459159 to Rodriguez-Lence et al 2019a

2022-03-31T18:58:59Z

Scipediacontent moved page Draft Content 917459159 to Rodriguez-Lence et al 2019a

Scipediacontent: Created page with "== Abstract == FIDAMC(Fundación para la Investigación, Desarrollo y Aplicación de Materiales Compuestos) , has been investigating different technologies, under the f..."

2022-03-31T18:58:56Z

Created page with "== Abstract == FIDAMC(Fundación para la Investigación, Desarrollo y Aplicación de Materiales Compuestos) , has been investigating different technologies, under the f..."

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== Abstract ==

FIDAMC(Fundación para la Investigación, Desarrollo y Aplicación de Materiales Compuestos) ,  has been investigating different technologies, under the frame of several research projects funded by Clean Sky initiatives and Spanish governmental entities, in order to demonstrate that  thermoplastic can be directly manufactured via automation without autoclave consolidation and the full integration of the structure by co-consolidation method fusing together the skin and stringers in only one melting step.
Our Center is currently involved in an interesting project with a complete manufacturing solution of a thermoplastic wing skin using Automatic Fiber Placement (AFP) with assisted laser system as heating source techniques. This new Out-of-Autoclave procedure will be validated with ground/flying tests in 2020.
This paper provides an overview of several research projects aimed to develop the automated lamination and in-situ co-consolidation technology and includes a review of automated methods to lay up PEEK prepreg from the first AFP head, in cooperation  with the Spanish supplier MTORRES and installed six years ago in FIDAMC, the evolution of this machine and the up-to-the minute configuration of new Multi-tows head to produce the feasibility demonstrator panel with co-consolidated "T" shaped stringers and scale up the methods to the final stiffened wing panel to incorporate in Clean Sky 2 as Flight test Bed developed by Airbus.

== Full document ==
<pdf>Media:Draft_Content_917459159native-articles-230.pdf</pdf>

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 ==1 Introduction==
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 The technology advances are shown with the manufacturing of a feasibility demo with a prototype 8-tows head installed in a robot in MTORRES facilities in Pamplona on last september 2016. Different stringers styles (“T” shape) are produced using autoclave consolidation. An overview of the feasibility demo with target technology described previously is shown in Figure 8.
+[[File:Rodriguez-Lence_et_al_2019a-image12-c.png|centre|600x600px]]
-[[Image:Rodriguez-Lence_et_al_2019a-image12-c.png|600px]]
 <div class="center" style="width: auto; margin-left: auto; margin-right: auto;">

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 Following we ''are'' working on the evolution of the head and feasibility panels have been built to get enough maturity and fix the process window. More complex structures with integrated stringers have been manufactured by co-consolidation, that is to say, fusing together skin and stringers in a single melting step.
 <div class="center" style="width: auto; margin-left: auto; margin-right: auto;">
 <span style="text-align: center; font-size: 75%;">'''Figure 5. '''Evolution of thermoplastic structures with the improvements incorporated in the machine.</span></div>

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 The critical issue in the consolidation is to support the temperature necessary for the process a certain time. Laser profiles and velocity of the system establish the thermal history of the material. The velocity is direct related with the exposure time of the material to temperature, and with the heat transfer through the whole laminate [3].
 <div class="center" style="width: auto; margin-left: auto; margin-right: auto;">
 <span style="text-align: center; font-size: 75%;">'''Figure 3. '''Process window methodology.</span></div>
 Standard In-plane Shear Strength (IPSS) tests are used to assess the final degree of consolidation (DOC) in comparison with autoclaved samples because it is the dominating factor in the matrix-interface performance. Results are shown in Figure 4. The data show that specimens have 35-40% crystallinity and require neither further post-consolidation step nor vacuum bag and autoclave processing.
 <div class="center" style="width: auto; margin-left: auto; margin-right: auto;">
 <span style="text-align: center; font-size: 75%;">'''Figure 4. '''Results of mechanical strength of ISC laminates in comparison to laminates manufactured in autoclave.</span></div>

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 Existing machine, shown in Figure 2, consists in a laying up head that performs the process to melt, deposit and cool the thermoplastic unidirectional tapes, ply by ply on a tool. The process requires a continuous heating source by diode laser. An infrared camera is incorporated to the head to measure the temperature at the focal spot in the NIP (contact with roller) and length in the substrate and adjust the power and the angle of the laser optics. Other components of the machine head include an online compactation roller. Both incoming tape and substrate are consolidated by the action of this roller under controlled heat and pressure.
-The parameters to be controlled during the process to achieve enough consolidation were the lamination speed, temperature and thermal history and pressure. Laser profiles and velocity of the system establish the thermal history of the material. The velocity is direct related with the exposure time of the material to temperature, and with the heat transfer through the whole laminate.[3]
+The parameters to be controlled during the process to achieve enough consolidation were the lamination speed, temperature and thermal history and pressure. Laser profiles and velocity of the system establish the thermal history of the material. The velocity is direct related with the exposure time of the material to te
+mperature, and with the heat transfer through the whole laminate.[3]
-[[Image:Rodriguez-Lence_et_al_2019a-image6.png|600px]]
 <div class="center" style="width: auto; margin-left: auto; margin-right: auto;">
 <span style="text-align: center; font-size: 75%;">'''Figure 2. '''Thermoplastic machine characteristics.</span></div>

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 FIDAMC has investigated its out-of-autoclave (OoA) thermoplastic composite technology over several years under several research projects funded by Clean Sky initiatives and Spanish governmental entities, aiming that thermoplastic can be directly manufactured via automation without autoclave consolidation and the full integration of the structure by co-consolidation method fusing together skins and stringers in only one melting step thinking in large wing and fuselage panels [3].
 [[Image:Rodriguez-Lence_et_al_2019a_4323_rodriguez_fig1.png|600px]]
 <span style="text-align: center; font-size: 75%;">'''Figure 1.''' Evolution of technology level.</span></div>

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