In Situ Characterization of the Reaction-Diffusion Behavior during the Gradient Interphase Formation of Polyetherimide with a High-Temperature Epoxy System

This study presents two novel methods for in situ characterization of the reaction-diffusion process during the co-curing of a polyetherimide thermoplastic interlayer with an epoxy-amine thermoset. The first method was based on hot stage experiments using a computer vision point tracker algorithm to detect and trace diffusion fronts, and the...

Development of innovative automated solutions for the assembly of multifunctional thermoplastic composite fuselage

In this study, the development of innovative tooling and end-effector systems for the assembly of a multifunctional thermoplastic fuselage is presented. The increasing demand for cleaner and new aircraft requires utilising novel materials and technologies. Advanced thermoplastic composites provide an excellent material option thanks to their...

In-line variable spreading of carbon fibre/thermoplastic pre-preg tapes for application in automatic tape placement

This study investigates a device for in-line continuous spreading of carbon fibre/thermoplastic pre-preg tape for potential application in the Laser-Assisted Automatic Tape Placement (LATP) laminate manufacturing process. The spreading device allows variable tape width to be achieved locally during lay-up. Integration of this device in the...

Static test of a variable stiffness thermoplastic composite wingbox under shear, bending and torsion

Automated manufacturing of thermoplastic composites has found increased interest in aerospace applications over the past three decades because of its great potential in low-cost, high rate, repeatable production of high performance composite structures. Experimental validation is a key element in the development of structures made using this...

Fabrication factors influencing mechanical, moisture- and water-related properties of mycelium-based composites

Mycelium-based composites result from the growth of filamentous fungi on organic materials such as agricultural waste streams. These novel biomaterials represent a promising alternative for product design and manufacturing both in terms of sustainable manufacturing processes and circular lifespan. This study shows that their morphology,...

Properties of a thermoplastic composite skin-stiffener interface in a stiffened structure manufactured by laser-assisted tape placement with in situ consolidation

A critically important consideration of stiffened structural panels is the interfacial properties between skin and stiffener. In the present study a novel implementation of laser-assisted tape placement (LATP) was used to produce a representative skin-stiffener of a wingbox from carbon fibre reinforced PEEK. First, a stiffener is manufactured...

Analysis of void formation in thermoplastic composites during resistance welding

The process-induced voids during resistance welding of glass fabric-reinforced polyetherimide was investigated. The mechanisms of void formation in adherends, in particular, the residual volatile-induced voids and the fibre de-compaction-induced voids, were analysed. Due to the non-uniform temperature and stress distributions in the joints...