27-31 July 2009, Edinburgh, UK

Manufacturing Technologies "Siphon Impregnation": The Development of a New Method for Impregnation during Filament Winding A Miaris, M Päßler, J Lichtner, R Schledjewski (Institut für Verbundwerkstoffe GmbH) A new impregnation system for the wet out of rovings during the filament winding has been developed. The siphon is a close type impregnation system without any moving parts. Experiments show good impregnation quality, low resin waste, and longer run times in comparison with open bath systems. (C3:1) Fiber Metal Laminates Made by the VARTM Process BJ Jensen, RJ Cano, SJ Hales, ES Weiser (NASA) JA Alexa (Lockheed Martin) AC Loos (Michigan State Univ) WS Johnson (Georgia Inst of Tech) Fiber metal laminates (FMLs) are multi-component materials utilizing metals, fibers and matrix resins. Tailoring their properties is readily achievable by varying one or more of these components. Established FMLs like GLARE utilize aluminum foils, glass fibers and epoxy matrices and are manufactured using an autoclave. (C3:2) The Experimental Characterisation and Investigation of Prepreg Tack RJ Crossley, PJ Schubel, NA Warrior (Univ of Nottingham) Increasingly popular automated processes such as tape laying (ATL) depend heavily on prepreg tack for success. In the absence of a standardised method, a new test has been developed and utilised to establish the effects of operating conditions and determine a repeatable value for tack and compliance of commercial prepregs. (C3:3) Quality Aspects of and Thread Selection for Stitched Preforms P Mitschang (Institut für Verbundwerkstoffe GmbH) A Ogale (Schlimbach Business Solutions) Experimental studies show the influence of various sewing parameters on the preform manufacturing processes, preform quality, and quality and properties of fiber reinforced polymer composite. Correlations between ellipse formation phenomenon, sewing thread, and sewing machine parameters are established and can help to improve the overall preform and laminate quality. (C3:4) Numerical Modelling of the Filament Winding Process H Faria, A Rocha (INEGI) F Pires, A Marques (FEUP) A framework composed of several building blocks that allows the simulation of the filament winding process is described. The physical and thermo-chemical phenomena interacting at the layer/laminate level together with analytical description of the compaction and consolidation mechanisms were modelled and incorporated in finite element software. (C3:5) Wetting Behavior Between Fiber and Resin in Vacuum Assisted Resin Transfer Molding (VARTM) T Ohara, I Ueno, S Ogihara (Tokyo Univ of Science) K Watanabe (Mitsubishi Rayon Co., Ltd) The authors focus on wetting process of glass fibre-resin system in the vacuum assisted resin transfer moldings (VARTM). Penetration of the resin into the space between the fibres was detected from above and beneath the fibre bandle. Effects of resin temperature and internal pressure are discussed. (C3:6)

27-31 July 2009, Edinburgh, UK Numerical Simulation of Jigs and Tools for CFRP-Parts M Luenemann, H Apmann, M Stroeher (Airbus Deutschland GmbH) Composites gain an increasing importance in modern aviation industry. Also the respective jigs and tools have to be developed further since processing composites poses new requirements towards the tools due to the significant interdependence between the characteristics of the tool and the achievable quality of the part. This interrelation can no longer be predicted based on experience but has to be precisely evaluated. (C3:7) Automatic Handling of Dry Carbon Fabrics H Apmann, M Herkt, M Luenemann (Airbus Deutschland GmbH) In this paper, different systems for handling carbon fibre materials are discussed. Both dry fabrics and prepreg material can be handled by automated systems assisted by an industrial robot. Numerous tests have shown the maturity of these systems following development and realization revealing the potential for automation. As a further point, the automated production of stringers from prepreg as well as the preparation of dry performs for CFRP-frames are dealt with. (C3:8) Manufacture of a Rotor Blade Pitch Horn using Binder Yarn Fabrics F Weiland, C Weimer (Eurocopter) C Katsiropoulos, S Pantelakis (Univ of Patras) M Asareh, D Cartie, A Mills, A Skordos (Cranfield Univ) L Dufort, P De Luca (ESI Group) A Pickett (ESI GmbH) 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. (C3:9) Determination of Duty Cycle in Thermoset Pultrusion WA Khan, J Methven (Univ of Manchester) Advantages of preheating the precursors to increase the line speed in thermoset pultrusion are studied and the work has been extended to quantify for the first time the duty cycle of a typical process and thereby provide an estimate of the Specific Energy Consumption (SEC). The results of the analysis were compared with experimental measurements made using a Fluke 345 Power Meter. (C3:10) An Innovative Approach on Modular Joints for Carbon Fibre Reinforced Structures F Weyrauch (German Aerospace Centre) L Llopart (Premium Aerotec) F Strachauer (EADS IW) Within the EU-Project MOdular JOints a material driven design for aeronautics composite components based on T-, L-, H- and Pi-shaped joints was developed. This paper is focusing on the manufacturing steps for the Pi-shaped joints, including the preforming, the out-of-autoclave infusion and the pressure free bonding process. (C3:11) Inorganic Phosphate Textile Reinforced Cement Composite Moulds J Blom, P Van Itterbeeck, J Van Ackeren, J Wastiels (Vrije Univ Brussels) In order to meet the new demands of the industry, for example: reduction of production time, material reduction, cost saving and ecological aspects a new mould production technique will be presented. The aim of this research is the development of a mould technique which can replace the classic thermo harder or metal moulds, using textile reinforced cement. This mould type will even be applicable for the production of thermoplastic advanced composites. (C3:12)

27-31 July 2009, Edinburgh, UK Development of an Impregnation Technique for Glass Fibre Mats to Process Textile Reinforced Cementitious Composites O Remy, J Wastiels (Vrije Univ Brussels) A controllable impregnation of glass fibre structures used in textile reinforced cementitious composites can nowadays only be obtained at laboratory scale by hand lay-up means, hindering possible structural applications of this promising composite. This paper will discuss a recently developed impregnation technique. (C3:13) Development of an Adapted Process Technology for Complex Thermoplastic Lightweight Structures based on Hybrid Yarns W Hufenbach, F Adam, J Beyer, M Krahl, M Zichner, S Lin, U Hanke (TU Dresden) An efficient manufacturing process for cross section sandwich structures made of novel 3D-woven, knitted or stitched performs based on thermoplastic hybrid yarns was developed. For this purpose an adaptive tool concept with active kinematics and integrated heating-/cooling-system had to be provided. Consolidation of the focused continuous fibre reinforced sandwich structures takes place in a fast-stroke press. (C3:14) Applications of FRP Composites on Bend and Complicated Shape Structures T Hattori, T Hayakawa, M Yamaguchi, M Yamashita (Gifu Univ) The FRP show a remarkable effect when the long continuous fibers are placed along with the stress flow especially at the stress concentration points. In this paper we developed new moulding process, in which we perform the fiber cutting just after continuous fiber placement process and just at the low stress area. (C3:15) Automated Spray Deposition for Net-Shape Carbon/Epoxy Compression Moulding R Luchoo, LT Harper, NA Warrior (Univ of Nottingham) A Dodworth (Bentley Motors Limited) Details are presented of an automated process for manufacturing net-shape charges for compression moulding, using a spray deposition technique. The novel process uses a resin-spray technique to position and hold fibres onto the tool face. The process is intended for producing structural components using discontinuous fibres for medium volume applications. (C3:16) An Environmentally Friendly Modified Wet-Filament Winding Process N Shotton-Gale, S Pandita, M Paget, C Wait, G Fernando (Univ of Birmingham) A modified wet-filament winding process was developed where the resin and hardener are stored separately and pumped on-demand through a static-mixer to an impregnation unit to impregnate the fibre tows. This new manufacturing technique results in a significant reduction in the consumption of solvents and generation of waste resin. (IC3:1) Thermoplastic Braid Pultrusion M Milwich (ITV Denkendorf) At ITV Denkendorf, a pulbraiding equipment was installed to enhance torsional stability of thin walled rectangular profiles (Twintex hybrid yarns) and tubular profiles (thermoset matrix) were produced. Optimized process- and fibre handling parameters resulted in profiles with up to 25°braiding angle with high surface quality, good consolidation and uniform dimensions. Further research work is carried out on realising hollow tubular profiles with enhanced bending stiffness and damping properties using biomimetic approaches. (IC3:2)

27-31 July 2009, Edinburgh, UK Solid State Nd:YAG Laser Cutting of CFRP Sheet: Influence of Process Parameters on Kerf Geometry and HAZ C Leone, V Lopresto, A Pagano, I de Iorio (Univ of Naples) Pulsed Nd:YAG laser was used in cutting operation on 1 mm GFRP plates changing the pulse duration and the pulse energy at different cutting speed. The aim was to study the process parameters influence on the kerf geometry and HAZ extension. It was found that a decrease of pulse duration allows to obtain high quality cutting and narrow HAZ. (IC3:3) Double Vacuum Bagging (DVB) Process Coupled with Quickstep Process LA Khan, A Nesbitt, RJ Day (Univ of Manchester) Z Khan (NUST In order to reduce cure cycle time and improve the void removal efficiency during processing of composite laminates, a double vacuum bagging (DVB) technique has been coupled with the Quickstep process. Panels have been produced using an optimized Quickstep cure cycle and then compared with ones manufactured using a cycle with the DVB technique. (IC3:4) Cure Process Design to Manufacture a Complex Shape Composite Component by a Closed Die Technology L Tersigni, L Sorrentino, C Bellini (Univ of Cassino) L Carrino (Univ of Naples) A Leone, E Mostarda (Agusta Westland) This paper focuses on the problems of both structural integrity, and dimensional and/or geometrical inaccuracies after the cure process of the complex shape composite components manufactured by closed die technology. In particular, in this paper a preliminary design methodology of cure process to avoid these problems is described. (IC3:5) Optimization of Lamp Positions in the UV Curing of 3-Dimensional Composite Components Manufactured Using The RIDFT Process OS Adewuyi, O Okoli , D Jack (Florida A&M Univ) A simple method for curing of curvilinear composite components manufactured with the RIDFT process is proposed. A continuously differentiable multivariate optimization model was developed. Davidon-Fletcher-Powell algorithm was used for predicting lamps’ optimum positions. Mechanical and rheological tests were carried out to determine the veracity of the model developed. (IC3:6) Fabrication of Micro-Type Diamond Wheels using UV- Lithography and Composite Electroforming Technique S-Y Luo, C-H Yu, S-J Yan, J-N Huang, Y-S Liu (Huafan Univ) This study will use the techniques of UV-lithography and precision composite electroforming to fabricate the micro nickel matrix diamond wheels. The microlithography parameters of negative photoresist JSR THB-151N on aluminum substrate and micro composite electroforming parameters were discussed. Finally, the processes and methods for the design and manufacture of micro diamond wheels were established. (IC3:7) Manufacturing Process of 100% Vegetable Composite Plates: Effect of the Flax-Tow Grading on Mechanical and Physical Properties N El Hajj, Z Aboura, M Benzeggagh (UMR/CNRS) R-M Dheilly, M Queneudec T'kint (Univ de Picardie Jules Verne) Nowadays, the request to use materials preserving the environment is in strong growth.The good mechanical properties and low density of flax fiber allow them to be used as reinforcement in polymeric matrix composite. The innovation of this research consists in finding a technique to fabricate 100 % vegetable composite plates from flax-tow. However, there is a need to compare mechanical and hydrical properties of composite plates with differing flax-tow grades to make an optimal choice. (IC3:8)

27-31 July 2009, Edinburgh, UK An Advanced Resin Transfer Moulding System for the Production of Advanced Composite Materials L Broadbent, R Bland, S Leonard-Williams (Composite Integration) S Sharma, J Summerscales (Univ of Plymouth) The aerospace composites industry is considering high-performance single-part epoxy resins for structural components. These are quasi-solid at ambient temperatures. A new resin delivery system has been developed which is compliant with the critical requirements imposed by the aerospace industry. (IC3:9) New Direct Processing Technology for Thermoset Compression Moulding Parts: Direct Sheet Moulding Compound T Potyra, D Schmidt, F Henning (Fraunhofer Institute for Chemical Technology) In order to improve quality issues as well as to decrease the price for Sheet Moulding Compound a one-step direct processing technology has been developed. This presentation should give an overview of this new direct processing technology as well as its characteristics and resulting mechanical properties. (IC3:10) Optimisation and Spectroscopic Experiments of Cationic Epoxy Resin Formulations for the Application of Photocuring of Deep Resin Mediums using Side Emitting Optical Fibres AD Alobaidani, D Furniss, MS Johnson (Univ of Nottingham) The photocuring behaviour of several cationic epoxy resins is investigated by curing thick components. Varying the compositional ratio of the epoxy resin formulation resulted in significantly faster curing of a 5 mm thick laminate compared to other commercially available epoxy resins used for adhesive applications. The optimised epoxy based formulations showed low absorption spectrum. Photosensitizers reduce the curing efficiency of thick components. (IC3:11)

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