Advanced Manufacturing: Polymer and Composites Science

In heat transfer analysis of AFP process using a hot gas torch, the convective heat transfer which occurs between the hot gas flow generated by a torch nozzle and a composite substrate plays an important role in the heat transfer mechanism. In order to model the convective heat transfer, a local heat flux equation q″=h (ΔT) is utilized where q″ is the energy flow per unit of area per unit of time, h is the convective heat transfer coefficient between the hot gas torch and the composite surface, and ΔT accounts for the temperature difference between the two media. This coefficient h is dependent on various number of parameters such as nozzle geometry and its configuration relative to the surface of the substrate, type and configuration of the roller, gas flow rate, temperature of the gas, type of the gas etc. Researchers on the heat transfer analysis for automated composites manufacturing have used values of h that vary from 80 W/m2K to 2500 W/m2K. This large range gives rise to uncertainties in the determination of important behavior such as the temperature distributions, residual stresses, and deformations of the composite structures due to the manufacturing process. The reason for these large differences can be due to the differences in the process parameters in each of the studies. The process parameters can include the volume flow rate of the hot gas, the gas temperature, the distance between the nozzle exit and the surface of the composite plate, the angle of the torch with respect to the surface of the substrate etc. In addition, the value of the h coefficient may not be constant over the heating length of the process. The purpose of this paper is three fold: 1. To investigate the AFP process parameters that may affect h. 2. To investigate different methods for the determination of h, and 3. To develop a procedure for less-time-consuming determination of h for the purpose of analysis for residual stresses and deformations.

Omid Aghababaei Tafreshi

Suong Van Hoa

Farjad Shadmehri

Duc Minh Hoang

Daniel Rosca

Advanced Manufacturing Polymer & Composites Science

Determination of convective heat transfer coefficient for automated fiber placement (AFP) for thermoplastic composites using hot gas torch

热气炬用于热塑性复合材料自动纤维铺放（AFP）对流换热系数测定

The production of polymeric fibers by the electrospinning technique stands out as being simple, accessible, versatile and with potential use of polymer microfibers in many areas of science and technology. In this article, polymeric microfibers of PBAT/PLA and carbon nanotubes were obtained using a Fractional Factorial Design. The statistical results, the optical microscopy and scanning electron microscopy (SEM) showed that the addition of MWCNT’s had an influence in the diameter of the fibers (1.16 ± 0.22 µm), so that its incorporation decreased the value of the diameter, also they were more uniform and homogeneous. Besides, the MWCNT’s provided the fibers a better mechanical resistance, probably being inside the fibers, as well as showed in the analysis of wettability by contact angle.

Andressa Giombelli Rosenberger

Janice Caroline Hardt

Douglas Cardoso Dragunski

Franciele Fernanda da Silva

Paulo Rodrigo Stival Bittencourt

Reinaldo Aparecido Bariccatti

Edvani Curti Muniz

Marcia Regina Simões

Josiane Caetano

Use of experimental design to obtain polymeric microfibers with carbon nanotubes

实验设计在制备含碳纳米管聚合物微纤维中的应用

During co-cure of honeycomb core sandwich panels, composite facesheets are cured and concurrently bonded to the core, introducing complex interactions that can lead to unsatisfactory bond-line formation. In this work, an in situ co-cure fixture is employed to directly observe the adhesive during processing and identify defect formation mechanisms specific to the bond-line. Relating fillet quality to imposed core pressure reveals the non-linear effect of core pressure. High pressures suppressed voids; intermediate pressures resulted in void growth and entrapment within deformed fillets; and low pressures led to void rupture and small, irregular fillets. Experimental results aided in developing a model to predict void growth in the bond-line. The findings presented here provide insight into the physics controlling the adhesive bond-line evolution during co-cure, which can inform manufacturing decisions to produce higher-quality honeycomb core sandwich structures.

Daniel Zebrine

Mark Anders

Timotei Centea

Steven Nutt

Path-dependent bond-line evolution in equilibrated core honeycomb sandwich structures

平衡芯体蜂窝夹层结构中的路径依赖粘结线演化

Potential links between pressure conditions during co-cure of honeycomb sandwich panels, the extent of gas flow through facesheet and bond-line, and the level of permeability in the cured skin were evaluated. Half-sandwich structures comprised of fiber-reinforced polymer facesheets, film adhesive, and core were fabricated using a custom-built lab fixture. Autoclave, bag, and core pressures were varied to produce controlled, constant pressure differences during cure, and the resulting skins were tested for permeability using a fixture constructed to measure gas flow rate across the skins and to locate gas flow pathways. Facesheet cross-sections were analyzed to evaluate porosity. Porosity and the number of gas flow pathways were correlated to permeability, but significant gas flow was possible without high void content or with few channels, as pressure differentials led to complex variations in permeability. Overall, the study provides new insights into gas transport during composites processing and manufacturing, and the results provide guidance for modifying manufacturing processes to ensure part quality.

Trisha Palit

Permeability of co-cured honeycomb sandwich skins: effect of gas transport during processing

共固化蜂窝夹芯蒙皮渗透性：加工过程中气体传输的影响

Out-time and moisture absorption in prepregs are generally unavoidable in an industrial setting, where prepreg layup can take weeks. The resin cross-linking and viscosity increase that occurs during out-time can reduce resin flow during a specified cure cycle, causing porosity. In this study, a flow-optimized cure cycle was developed, leveraging both flow level and time during out-of-autoclave (OoA) processing. First, predictive cure kinetics and viscosity models were used to model viscosity evolution under selected cure conditions, accounting for initial out-times and humidity conditioning. To quantify resin flow, an ‘effective flow number’ metric was defined as the integration of inverse viscosity evolution until the resin gelation point. The method described revealed that a rapid heating rate achieved by use of advanced tooling was essential to achieve a high effective flow number. The experimental results showed that the effective flow number is a useful criterion to limit flow-induced defects. The method presented also extends the boundary (by 175%) of the manufacturer’s specified out-life for OoA prepreg materials.

D. Kim

S. R. Nutt

Effective cure cycle development via flow optimization and advanced cure environments

通过流优化和先进固化环境实现有效的固化周期开发

Navin Kumar Balasubramainian

Logesh Kothandaraman

T. Sathish

Jayant Giri

Muhammad Imam Ammarullah

Optimization of process parameters to minimize circularity error and surface roughness in fused deposition modelling (FDM) using Taguchi method for biomedical implant fabrication

使用田口方法优化熔融沉积成型（FDM）中的工艺参数以最小化圆度误差和表面粗糙度，用于生物医学植入物制造

Short carbon fiber-reinforced polymers (SCFRPs) are used in automotive and aerospace applications because of their superior strength-to-weight ratio and resistance to fatigue and thermal stresses. Fused filament fabrication (FFF) is considered an efficient fabrication method for SCFRP components, yet optimizing process parameters for specific performance targets is non-trivial and resource consuming. Herein, a multi-objective Bayesian optimization (MOBO) framework for FFF-based SCFRP fabrication has been developed to fine-tune process parameters to optimize the trade-off between tensile strength and weight of the products. Initial random experiments were conducted on printed samples with different infill densities, printing speeds, and layer heights to evaluate their impact on specific tensile fracture energy (STFE) and component weight. These parameters were found to influence STFE and weight significantly. Data-driven sequential experimentation was then applied to identify a set of optimal values for these parameters. A surrogate-based optimization framework was utilized, and optimal points were determined through iterative refinement, with the process culminating when further iterations did not significantly enhance weight or STFE, indicating Pareto optimality. The efficacy of the methodology was demonstrated by identifying FFF parameters that achieve Pareto optimal STFE-to-weight ratios in nine iterations. This data-driven approach provides an efficient route to process optimization compared to heuristic and computational methods, streamlining the SCFRP design process via FFF and potentially extending to other composite systems and manufacturing processes.

Olivia Fulkerson

Erik Inman

Aditya Rane

Hadi Noori

Akash Deep

Srikanthan Ramesh

Multi-objective Bayesian optimization of fused filament fabrication parameters for enhanced specific fracture energy in PLA-carbon fiber composites

多目标贝叶斯优化用于增强PLA-碳纤维复合材料断裂能量的熔融沉积成型参数

Carbon fiber reinforced polyetheretherketone (CF-PEEK) samples were fabricated using material extrusion. These additive manufactured green bodies are later processed to their final application as ceramic matrix composites (CMC) by the liquid silicon infiltration (LSI) route. Past studies showed that the application of material extrusion for the fabrication of CMC requires an additional stabilization-step after 3D-printing in order to prevent the remelting of CF-PEEK during the high temperature process of pyrolysis. The thermally induced crosslinking of the CF-PEEK parts ensured shape accuracy and avoided remelting during the pyrolysis afterwards but is limited by the melting temperature of PEEK (Tm ∼ 343 °C). The study revealed a correlation between the annealing conditions time and temperature and the degree of crosslinking. Based on the analytical results from differential scanning calorimetry (DSC), a kinetic model was calculated, allowing predictions in dependence of the annealing temperature and time. Rheological and shape stability investigations of thermally annealed specimens verified the analytic results. The main findings of the study highlight an increasing degree of crosslinking with increasing annealing temperature and time.

Wolfgang Freudenberg

Felix Wich

Jalena Best

Elena Moukhina

Tim Scherzer

Holger Ruckdäschel

Nico Langhof

Stefan Schafföner

Thermo-oxidative crosslinking of carbon fiber reinforced PEEK (Polyetheretherketone) for additive manufactured ceramic matrix composites

碳纤维增强聚醚醚酮的热氧化交联用于增材制造陶瓷基复合材料

The utilization of bio-based materials for the manufacturing of fiber-reinforced polymer composites is gaining importance under the sustainability paradigm. The identification of suitable process parameters and limited process reproducibility remain among the major challenges to enhance the industrial application potential of bio-based composites. This is especially relevant, as the manufacturing process influences composite quality, economic performance and environmental impacts. This study compares Resin Transfer Molding and Vacuum Assisted Resin Infusion for two sets of process parameters in order to manufacture a composite plate consisting of a flax-fiber textile impregnated with a partially bio-based epoxy matrix. Process quality is described through statistical analysis of processing and composite properties, and performance in terms of process replicability and reliability using performance estimates. Processing parameters were selected to depict a range of manufacturing scenarios that were suitable for the selected bio-based material system from curing for 180 min at 60 °C to curing for 30 min at 100 °C. For an identical set of process conditions, Resin Transfer Molding outperforms Vacuum Assisted Resin Infusion in terms of tensile and flexural characteristics. Conversely, the latter shows the strongest fiber-matrix adhesion and the most homogeneous impregnation. Whereas manufacturing at lower temperature leads to positive effects on composite quality, higher processing temperature with shorter curing cycles achieve highest process performance in terms of Pp and Ppk indices. An additional annealing at 120 °C neither increases composite quality nor reduces manufacturing-induced variability. Results depend on processing differences and indicators to determine process performance, as well as methodological choices.

Ulrike Kirschnick

Michael Feuchter

Bharath Ravindran

Moritz Salzmann

Ivica Duretek

Ewald Fauster

Ralf Schledjewski

Manufacturing bio-based fiber-reinforced polymer composites: process performance in RTM and VARI processes

生物基纤维增强聚合物复合材料制造：RTM和VARI工艺中的过程性能

Multilayer plastic (MP) commonly used in food and beverage packaging is difficult to recycle due to its layered structure, resulting in its accumulation over time; the consequent environmental harm is further exacerbated by its short lifespan. This study investigates recycled low-value MP as a modifier for polymer-modified bitumen (PMB). However, the difference in polarity between MP and PMB mixtures is a challenge, resulting in their poor compatibility and reduced mechanical properties. To overcome this, low-value MP was treated with atmospheric cold plasma and thermal oxidation to enhance its compatibility with PMB. The results indicate that plasma and thermal treatments increase the hydrophilicity of low-value MP through the formation of low-molecular-weight oxidized molecules containing hydrophilic hydroxyl (–OH) and carbonyl (C = O) groups that act as an intermediary boundary layer between the low-value MP and asphaltene-rich bitumen. Further, the optimal oxidation conditions for MP are revealed as 60 s of plasma treatment followed by heating at 150 °C for 60 min. Mixtures of PMB and optimally oxidized MP have optimal compositions of 1 wt.%, with ductility and penetration values of 87.7 cm and 57.4 mm, respectively.

Adam Febriyanto Nugraha

Calvin Simon Andreas Lumban Gaol

Mochamad Chalid

Gusaimas Matahachiro Hanggoro Himawan Akbar

Havid Aqoma

Enhancing the compatibility of low-value multilayer plastic waste in bitumen mixtures using atmospheric cold plasma and thermal oxidation

利用大气冷等离子体和热氧化提高低价值多层塑料废弃物在沥青混合料中的相容性

Abbreviation	Adv. Manuf. Polym. Compos. Sci.
Journal Impact	1.62
Quartiles(Global)	ENGINEERING, MANUFACTURING(Q3)

ISSN	2055-0340, 2055-0359
h-index	23

Publication Information	Publisher: Taylor and Francis Ltd.，Publishing cycle: ，Journal Type: journal，Open Access Journals: Yes
Basic data	Year of publication: 2015，Proportion of original research papers: 100.00%，Self Citation Rate:5.60%， Gold OA Rate: 96.43%
Journal Fees	$1250Details
Average review cycle	网友分享经验：16 Weeks

Advanced Manufacturing: Polymer and Composites Science

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