TheSaLab – Fundamentals of manufacturing thermoplastic sandwich structures using laser-based in-situ thermoplastic automated fiber placement.

The production of thermoplastic sandwich structures using conventional methods is currently limited to flat components. Isolated approaches to the production of three-dimensional structures require highly complex tools and multi-step manufacturing processes and are also limited to a specific shape. Thermoplastic Automated Fiber Placement (TAFP), on the other hand, offers a flexible fiber composite manufacturing process. A comprehensive understanding of the process already exists for processes in which similar semi-finished products are used. However, there is a lack of knowledge about the mechanisms of action and the nature of the optical-thermomechanical interactions when depositing anisotropic tapes on isotropic foam structures. 

Objectives

The aim of this project is to develop a fundamental understanding of the relationships between optical-thermomechanical interactions in the heating and joining zone when depositing carbon fiber-reinforced thermoplastic tapes on thermoplastic foam cores using laser-based TAFP.

Benefits

By generating a fundamental understanding, the basis for producing individually curved thermoplastic sandwich structures using laser-based TAFP is created.

Approach

The first step is to examine the optical interaction of the laser radiation with the foam material and the prepreg tapes and to determine the power distribution in the heating zone resulting from the reflection, absorption and transmission characteristics of the two joining partners as a function of the laser settings on the basis of a model. Furthermore, the foam and consolidation roller behavior under process parameters is mechanically characterized and transferred to material models. The results of the investigations are then combined in a thermomechanical process model and validated.

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Contact Christopher Schmitt via email at schmitt@ifw.uni.hannover.de or by phone at +49 4141 77638 23.