Insertion of large diameter through-thickness metallic pins in composites

Existing Through-Thickness Reinforcement (TTR) methods for laminated composites using semi or fully rigid reinforcing elements, like tufting, stitching, and z-pinning, present limitations on reinforcing element geometry, strength, and stiffness. Where these application envelopes are exceeded, TTR element insertion results in unacceptable levels of damage to both the composite and/or TTR elements. Here, we demonstrate that low-speed insertion of rigid reinforcements into heated prepreg preforms is a feasible and robust reinforcement process capable of providing accurate TTR element placement with minimal tow disturbance compared with existing methods for similar pin sizes. The insertion process is characterised with respect to insertion forces, and mesoscale laminate deformation/damage for carbon-benzoxazine prepreg preforms. The research investigates the influence of pin leading edge on insertion for a range of pin diameters (1.2, 1.5, and 2.0 mm) and preform consolidation states, describing low insertion forces and good quality laminate preforms. Insertion forces increase with pin diameter, typically resulting from increased pin-tow contact area and friction. Large diameter sizes and low insertion forces expand the range and forms of materials that can be inserted compared to existing TTR methods and show that this method can potentially be transferred to benefit work on composite hole creation, joining, and repair

Developing cure kinetics models for interleaf particle toughened epoxies

In this study, we investigated the cure kinetics behaviour of the commercial Hexply® M21 thermoplastic interleaf epoxy resin system. Dynamic, isothermal, and cure interrupted modulated differential scanning calorimetry (mDSC) tests were used to measure the heat flow of the system, and semi-empirical models were fitted to the data. The cure kinetics model describes the cure rate satisfactorily, under both dynamic heating and isothermal conditions. The glass transition temperature was described using the DiBenedetto equation and showed that heating rate can influence formation of the network; therefore cure schedule must be controlled carefully during processing

One-dimensional approximation of heat transfer in flashlamp-assisted automated tape placement

A computationally efficient heat transfer simulation of flashlamp-assisted automated tape placement (ATP) is put forward in this work. The simulation combines distinct 1D finite element models representing the tow, the deposited material, and the resulting stack with appropriate transfer of temperature information to ensure field continuity. Direct comparison against a validated 2D model of ATP shows good agreement in the irradiation region, underneath and beyond the roller vicinity with errors up to 14°C. The combined solution of 1D models requires only 1-2% of the computational effort needed for an equivalent 2D analysis without compromising results resolution, whilst it is better suited for providing the full material temperature history throughout consecutive processing cycles. The accuracy and fast computation render this method appealing for studies which require an iterative execution of the model in a practical timeframe such as in optimisation schemes, inverse solutions, training of surrogate models and stochastic simulation.Engineering and Physical Sciences Research Council (EPSRC): EP/L015102/

In-process nip point temperature estimation in automated tape placement based on analytical solution and remote thermal measurements

The optimisation and control of automated tape placement (ATP) requires fast analysis tools able to utilise process data for predictions and monitoring. In this study, a strategy for in-process estimation of nip point temperatures is proposed. The method is based on a combination of two one-dimensional analytical solutions of heat transfer in ATP using temperature data measured on the tool surface, combined with an inverse solution for the estimation of power delivered by the heating device on the composite surface. The performance of the method is examined against a validated finite element model. Approximations of nip point temperature show good correlation for different tool materials, with an average error of 15°C and a maximum of 50°C which is satisfactory for the processing of high-temperature thermoplastic materials. The analytical scheme offers real-time estimations of the nip point temperature with the potential to be used for process control of ATP

Metal foam recuperators on micro gas turbines: Multi-objective optimisation of efficiency, power and weight

Small size and high efficiency of micro gas turbines require a higher surface-to-volume ratio of recuperators. Conventional recuperators can achieve a range of 250–3600 m2/m3. Advances in materials and manufacturing, such as metal foams, can increase significantly the exchange surface and improve compactness ranging approximately from 500 to over 10,000 m2/m3, due to their exceptional micro geometry. The main advantage is that the increase of surface area does not impact the cost of the heat exchanger as much as conventional recuperators due to their easy manufacturing. This work addresses the optimisation of the recuperator using multiple objectives satisfying efficiency, power output and weight criteria, offering a holistic approach that takes into account the entire system rather than individual components or channels. A model is developed to represent the performance of a compact heat exchanger in micro gas turbines. The recuperator is an annular heat exchanger with involute profile filled with porous media in a counterflow arrangement on the hot and cold sides. The model allows the evaluation of the effect of the recuperator geometry features on the electrical efficiency, power output and weight savings in a micro gas turbine. Existing models for the global heat transfer coefficient, effective thermal conductivity, surface area and pressure drop of porous media are selected and implemented. The design variables of multi-objective are the pore density, porosity and number of channels, whilst the objectives are the overall electrical efficiency, power output and recuperator weight. The problem is solved using the Non-Dominated Sorting Genetic Algorithm (NSGA-II) to determine an approximation of the Pareto front, whilst the accuracy of the approximation is assessed against the solution obtained by an exhaustive search. The comparison shows that NSGA-II outperforms an exhaustive search by at least 90 % in terms of computational efficiency. These results allow the quantification of the impact of metal foam technology on performance metrics of the recuperator as well as the entire system. This quantitative analysis provides valuable insights into the behaviour of metal foam recuperators in micro gas turbines. An optimal design with 30 % efficiency and 28 kW power output appears in pore densities of approximately 10 and 20 pores per inch (PPI) for the air and gas side respectively, and a porosity of 85 %, which leads to a state-of-the-art recuperator weight of 48 kg. The efficiency improvement over the industry standard is 15 %, with only a 2.5 % reduction in power output

Manufacture of a rotor blade pitch horn using binder yarn fabrics

The use of binder yarn fabrics in rotor blade applications is investigated in this work. A preforming procedure is incorporated in manufacturing, resulting in higher degree of automation and a reduction of process steps. The performance of the process is evaluated with respect to cost savings compared to prepregging technologies

Real time uncertainty estimation in filling stage of RTM process

Surrogate models validation: includes comparison between FE model and surrogate modelSensors data: includes the response of the three lineal sensorsReal time uncertainty estimation: includes the results of the inversion procedurePrior model: confidence intervals using prior knowledgePost model: confidence intervals using inversion solutionCDF Filling time estimation: Cumulative density function of filling time estimation at different times during filling processSimCoDeQ (project ID: 686493)

Insertion of large diameter through-thickness metallic pins in composites: dataset

Force vs Displacement Data.xlsx - Contains all the raw force versus displacement data for the insertion tests carried out in the associated publication.Thermal Ageing Analysis.xlsx - Contains the DSC data (time, temperature, rev heat capacity and rev heat flow) for Bx180-220 prepreg under ageing regimes in the associated publication.A “Smart” Self-monitoring composite tool for aerospace composite manufacturing using Silicon photonic multi-sEnsors Embedded using through-thickness Reinforcement technique

Assessment of the benefits of 3D printing of advanced thermosetting composites using process simulation and numerical optimisation

3D printing of continuous fibre reinforced thermosetting matrix composites is set to revolutionise composite manufacturing practice. The potential of curing additively is anticipated to bring significant improvement in terms of increasing process speed, producing geometries that are inaccessible with current processing routes and reducing detrimental exothermic effects during the process. This study presents a comparison between the curing stage of the 3D printing and standard batch processing for carbon fibre/epoxy components of varying thickness and size. An optimisation methodology links simulation of the cure using Finite Element solver Abaqus with a Genetic Algorithm capable of dealing with multi-objective problems. Optimal cure cycles to minimise both process time and temperature overshoot in 3D printing and batch processing are identified and the optimal trade-offs compared. The results highlight that temperature overshoot reduction up to 85% is possible and that the intrinsic additive nature of the 3D printing allows eliminating the dependence of temperature overshoot on thicknesses and producing component with thicknesses that are very difficult to manufacture conventionally. This allowed the development of a simplified cure model to scale up the process. The outcome of this analysis showed that thin components can be 3D printed within few hours whilst thick components in tens of hours which make 3D printing favourable against conventional processing