JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 30
MANUFACTURING thermoplastics
Fig. 11: Crystallinity rate
versus cooling rate
Fig. 12: TMA curve
The manufacturing process challenge
A first composite rotor hub made of a
thermoplastic matrix and carbon fibre was
built for a demonstrator. It was successfully
tested on a test bench and in flight. During
the development phase, one of the main
difficulties was to obtain the right quality
level. This first experience showed that the
key manufacturing issues are:
- The consolidation cycle strategy due to the
part thickness;
- The suppression of porosities, waves,
micro-delaminations in the thickness
variation areas;
- The high-temperature process inducing
geometrical constraints and dilatation
effects.
To control these key characteristics and
confirm previous trials, tests were conducted on technological parts using an
evolutionary mould, leading to the creation
of a geometry part close to "2/5" of the hub.
The part dimensions were chosen to be
representative of the hub, while complying
with the size capacity of the laboratory press
infrastructure. The approach was to increase
the geometry complexity step by step.
Step 1 (Figure 14): Validating the feasibility
of a TP carbon part with a constant 85-mm
thickness.
Fig. 14: Constant-thickness part
Fig. 13: Overview of the
consolidation process
the mechanical properties.
The last part of the thermal-mechanical
analysis (TMA) curve (Figure 12) shows
a strong evolution reflecting, rather than
a thermal expansion, a change of phase
(solid-liquid) associated with a resin volume
increase.
On this graph, the expansion coefficient
appears to be roughly linear between the glass
transition temperature (Tg) (140°C) and
300°C. Other information available on this
30
material shows an expansion "peak" at 340°C,
corresponding to the fusion point of PEEK
resin.
So it is important to control the temperature
and the pressure cycles in order to optimize
the process and, consequently, the mechanical properties (Figure 13). This flexibility in
parameters adjustment makes it possible to
adapt the consolidation cycle to thick and
complex parts, in comparison with a TS
cycle controlled by an exothermic reaction.
jec composites magazine / N°116 October 2017
This step demonstrated:
- An excellent quality level in terms of porosity %, crystallinity rate, waviness, etc.;
- The controllability of such a carbon/
PEEK part.
Step 2 (Figure 15): Validating the feasibility
of a part with a variable thickness (85 to 32
mm).
Fig. 15: Variable-thickness part
The thermal cycle was adapted for the
changing thickness area. But due to some
Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #116 - October 2017
Cover
Edito
Opinion: Renewable energy
Contents
NEWS
In brief
JEC Asia
Agenda
BUSINESS
Strategy - Airbus strengthens its position in China
Database - The new technical database for composites
MANUFACTURING
NDT - New flexibility in 3D digitalisation and defect detection for batch composite production
Thermoplastics - Development of a carbonthermoplastic hub for the H160 helicopter
Feature Wind energy - An increasingly efficient sector
Market news - TPI Composites agreements with Gamesa and Vestas Wind Systems
Overview - Double digit growth again for the wind energy
Focus - lnside lndia’s wind turbine industry
Testimony - Strong growth in wind energy worldwide
Process - Perfect composite parts, thanks to the «direct infusion» process and resin conditioning
Technologies - Evolution of technologies and materials used in wind turbine blade manufacturing
Resin - New products for longer blades help to cut cost
SOLUTIONS
Aeronautics - lnnovative thermoplastic composite wing rib
Bike - Taking the lead with composites
Motorbike - lnnovative SLS front air inlet made with high-performance materials
Solar energy - Ultra-light photovoltaic panel based on polyamide honeycomb technology
TECHNOLOGY
NDT - Non-destructive evaluation of the mechanical strength of a TA6V4/composite bond using LASAT
Efficiency - Cost-efficient preforming using tailored textiles
Index
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JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 68
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Cover
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 2
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Edito
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Opinion: Renewable energy
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 5
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Contents
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 7
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - In brief
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 9
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - JEC Asia
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 11
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 12
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 13
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 14
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 15
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Agenda
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 17
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 18
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Ad1
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Ad2
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Strategy - Airbus strengthens its position in China
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 20
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 21
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Database - The new technical database for composites
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 23
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 24
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - NDT - New flexibility in 3D digitalisation and defect detection for batch composite production
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 26
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 27
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Thermoplastics - Development of a carbonthermoplastic hub for the H160 helicopter
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 29
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 30
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 31
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 32
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 33
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 34
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Market news - TPI Composites agreements with Gamesa and Vestas Wind Systems
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 36
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 37
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Overview - Double digit growth again for the wind energy
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 39
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Focus - lnside lndia’s wind turbine industry
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 41
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Testimony - Strong growth in wind energy worldwide
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 43
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Process - Perfect composite parts, thanks to the «direct infusion» process and resin conditioning
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Technologies - Evolution of technologies and materials used in wind turbine blade manufacturing
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 46
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 47
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Resin - New products for longer blades help to cut cost
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 49
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 50
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Aeronautics - lnnovative thermoplastic composite wing rib
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Bike - Taking the lead with composites
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 53
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Motorbike - lnnovative SLS front air inlet made with high-performance materials
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 55
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 56
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Solar energy - Ultra-light photovoltaic panel based on polyamide honeycomb technology
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - NDT - Non-destructive evaluation of the mechanical strength of a TA6V4/composite bond using LASAT
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 59
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 60
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 61
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 62
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Efficiency - Cost-efficient preforming using tailored textiles
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 64
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 65
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #116 - October 2017 - 67
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