Multi-scale characterization of carbon-fibre reinforced PEEK composites manufactured by laser-assisted tape placement
RESTIF Noé, LAIK Suzanne, PERON Mael, DAGHIA Federica, JACQUEMIN Frederic
download PDFAbstract. The Laser-Assisted Tape Placement forming process of thermoplastic composites enables the rapid production of laminates. However, it requires the tuning of the processing parameters, which is currently limited by a misunderstanding of the consolidation phenomena occurring during process and the interlaminar properties related with strong welded interfaces. This study aims at establishing correlations between physical properties and mechanical strength of welded thermoplastic composites, by using several methods and characterizations at different scales. Carbon-fibre reinforced PEEK (CF/PEEK) composites produced by a LATP process were investigatedby varying the Laser Setpoint Temperature (LST) and Tool Temperature (TT). The results show that laminates manufactured at a LST of 350 °C have high void content, with the location of the voids depending on the TT: at a TT of 25 °C (unheated tool), interply and intraply voids are present while for a TT of 250 °C they are mainly intraply. Laminates produced at a LST of 450 °C also have mainly intraply voids, although their void content is significantly lower than that of laminates produced at an LST of 350 °C. For laminates having mainly intraply voids, ILSS testing demonstrates failure by an intralaminar failure mode. An increase in intralaminar shear strength is observed as the intraply void content decreases and the degree of crystallinity increases, related to the LST and the TT. The combination of experimental techniques thus allowed to provide understanding on the influence of local physical properties of the composites manufactured by LATP on specific interface-related mechanical properties, and demonstrate that, despite variations of mechanical performances with processing conditions, interfaces are no longer a weak point within the laminates when the processing conditions allow for sufficient intimate contact to occur during the consolidation phase.
Keywords
Thermoplastic Composites, PEEK, Tape Placement, Experimental Characterization
Published online 4/24/2024, 10 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: RESTIF Noé, LAIK Suzanne, PERON Mael, DAGHIA Federica, JACQUEMIN Frederic, Multi-scale characterization of carbon-fibre reinforced PEEK composites manufactured by laser-assisted tape placement, Materials Research Proceedings, Vol. 41, pp 613-622, 2024
DOI: https://doi.org/10.21741/9781644903131-68
The article was published as article 68 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] R. Arquier, I. Iliopoulos, G. Régnier, and G. Miquelard-Garnier, “Consolidation of continuous-carbon-fiber-reinforced PAEK composites: a review,” Mater Today Commun, vol. 32, p. 104036, 2022. https://doi.org/10.1016/j.mtcomm.2022.104036ï
[2] W. Il Lee and G. S. Springer, “A Model of the Manufacturing Process of Thermoplastic Matrix Composites,” J Compos Mater, vol. 21, no. 11, pp. 1017–1055, 1987. https://doi.org/10.1177/002199838702101103
[3] F. Yang and R. Pitchumani, “Healing of thermoplastic polymers at an interface under nonisothermal conditions,” Macromolecules, vol. 35, no. 8, pp. 3213–3224, Apr. 2002. https://doi.org/10.1021/ma010858o
[4] F. Dave, M. M. Ali, R. Sherlock, A. Kandasami, and D. Tormey, “Laser transmission welding of semi-crystalline polymers and their composites: A critical review,” Polymers, vol. 13, no. 5. MDPI AG, pp. 1–52, Mar. 01, 2021. https://doi.org/10.3390/polym13050675
[5] A. Yousefpour, M. Hojjati, and J. P. Immarigeon, “Fusion bonding/welding of thermoplastic composites,” Journal of Thermoplastic Composite Materials, vol. 17, no. 4. pp. 303–341, Jul. 2004. https://doi.org/10.1177/0892705704045187
[6] T. K. Slange, L. L. Warnet, W. J. B. Grouve, and R. Akkerman, “Deconsolidation of C/PEEK blanks: on the role of prepreg, blank manufacturing method and conditioning,” Compos Part A Appl Sci Manuf, vol. 113, pp. 189–199, Oct. 2018. https://doi.org/10.1016/j.compositesa.2018.06.034
[7] O. Çelik, A. Choudhary, D. Peeters, J. Teuwen, and C. Dransfeld, “Deconsolidation of thermoplastic prepreg tapes during rapid laser heating,” Compos Part A Appl Sci Manuf, vol. 149, Oct. 2021. https://doi.org/10.1016/j.compositesa.2021.106575
[8] L. Amedewovo, L. Orgéas, B. de Parscau du Plessix, N. Lefevre, A. Levy, and S. Le Corre, “Deconsolidation of carbon fiber-reinforced PEKK laminates: 3D real-time in situ observation with synchrotron X-ray microtomography,” Compos Part A Appl Sci Manuf, vol. 177, Feb. 2024. https://doi.org/10.1016/j.compositesa.2023.107917
[9] K. Yassin and M. Hojjati, “Processing of thermoplastic matrix composites through automated fiber placement and tape laying methods: A review,” Journal of Thermoplastic Composite Materials, vol. 31, no. 12. SAGE Publications Ltd, pp. 1676–1725, Dec. 01, 2018. https://doi.org/10.1177/0892705717738305
[10] R. Arquier, H. Sabatier, I. Iliopoulos, G. Régnier, and G. Miquelard-Garnier, “Role of the inter-ply microstructure in the consolidation quality of high-performance thermoplastic composites,” Polym Compos, 2023. https://doi.org/10.1002/pc.27847
[11] M. Bonmatin, F. Chabert, G. Bernhart, T. Cutard, and T. Djilali, “Ultrasonic welding of CF/PEEK composites: Influence of welding parameters on interfacial temperature profiles and mechanical properties,” Compos Part A Appl Sci Manuf, vol. 162, Nov. 2022. https://doi.org/10.1016/j.compositesa.2022.107074
[12] C. Zhang et al., “Effect of porosity and crystallinity on mechanical properties of laser in-situ consolidation thermoplastic composites,” Polymer (Guildf), vol. 242, Mar. 2022. https://doi.org/10.1016/j.polymer.2022.124573
[13] J. Chen, K. Fu, and Y. Li, “Understanding processing parameter effects for carbon fibre reinforced thermoplastic composites manufactured by laser-assisted automated fibre placement (AFP),” Compos Part A Appl Sci Manuf, vol. 140, Jan. 2021. https://doi.org/10.1016/j.compositesa.2020.106160
[14] Z. Qureshi, T. Swait, R. Scaife, and H. M. El-Dessouky, “In situ consolidation of thermoplastic prepreg tape using automated tape placement technology: Potential and possibilities,” Compos B Eng, vol. 66, pp. 255–267, 2014. https://doi.org/10.1016/j.compositesb.2014.05.025
[15] A. J. Comer et al., “Mechanical characterisation of carbon fibre-PEEK manufactured by laser-assisted automated-tape-placement and autoclave,” Compos Part A Appl Sci Manuf, vol. 69, pp. 10–20, Feb. 2015. https://doi.org/10.1016/j.compositesa.2014.10.003
[16] D. J. Blundell and B. N. Osborn, “The morphology of poly(aryl-ether-ether-ketone).”
[17] O. Çelik, D. Peeters, C. Dransfeld, and J. Teuwen, “Intimate contact development during laser assisted fiber placement: Microstructure and effect of process parameters,” Compos Part A Appl Sci Manuf, vol. 134, Jul. 2020. https://doi.org/10.1016/j.compositesa.2020.105888
[18] F. O. Sonmez and H. T. Hahn, “Analysis of the on-line consolidation process in thermoplastic composite tape placement,” Journal of Thermoplastic Composite Materials, vol. 10, no. 6, pp. 543–572, 1997. https://doi.org/10.1177/089270579701000604
[19] C. M. Stokes-Griffin and P. Compston, “Investigation of sub-melt temperature bonding of carbon-fibre/PEEK in an automated laser tape placement process,” Compos Part A Appl Sci Manuf, vol. 84, pp. 17–25, May 2016. https://doi.org/10.1016/j.compositesa.2015.12.019
[20] M. A. Khan, P. Mitschang, and R. Schledjewski, “Identification of some optimal parameters to achieve higher laminate quality through tape placement process,” in Advances in Polymer Technology, Jun. 2010, pp. 98–111. https://doi.org/10.1002/adv.20177
[21] S. L. Gao and J. K. Kim, “Correlation among crystalline morphology of PEEK, interface bond strength, and in-plane mechanical properties of carbon/PEEK composites,” J Appl Polym Sci, vol. 84, no. 6, pp. 1155–1167, Feb. 2002. https://doi.org/10.1002/app.10406
[22] D. Ray et al., “Fracture toughness of carbon fiber/polyether ether ketone composites manufactured by autoclave and laser-assisted automated tape placement,” J Appl Polym Sci, vol. 132, no. 11, Mar. 2015. https://doi.org/10.1002/app.41643
[23] A. Maria El Bayssari, “Study and comprehension of the residual stresses and strains state in thermoplastic composite materials manufactured by tape placement.” [Online]. Available: https://theses.hal.science/tel-03888045
[24] P. A. Rodriguez and D. W. Radford, “A DMA-Based Approach to Quality Evaluation of Digitally Manufactured Continuous Fiber-Reinforced Composites from Thermoplastic Commingled Tow,” Journal of Composites Science, vol. 6, no. 2, Feb. 2022. https://doi.org/10.3390/jcs6020061
[25] X. Tardif et al., “Experimental study of crystallization of PolyEtherEtherKetone (PEEK) over a large temperature range using a nano-calorimeter,” Polym Test, vol. 36, pp. 10–19, 2014. https://doi.org/10.1016/j.polymertesting.2014.03.013
[26] S. L. Gao and J. K. Kim, “Correlation among crystalline morphology of PEEK, interface bond strength, and in-plane mechanical properties of carbon/PEEK composites,” J Appl Polym Sci, vol. 84, no. 6, pp. 1155–1167, Feb. 2002. https://doi.org/10.1002/app.10406