Timetable & Conference Programme - ITHEC 2020 · 2020. 9. 16. · In the timetable, the technical...

The ITHEC Time Zone Model:

- Conference Session I for Asia & Europe (9am - 1pm CET/MEZ (GMT+2))

- Networking Sessions with Virtual Round Tables

- Conference Session II for the Americas & Europe (3pm – 7pm CET/MEZ (GMT+2))

In the timetable, the technical sessions have ordinal

numbers (1-5), that are presented in the lecture

overview. Our Poster presentations have the ordinal

numbers 1-25, these are also presented in the

conference programme below. All abstracts are

linked via the table of contents.

Timetable & Conference

Programme

ITHEC 2020 - Virtual Edition - 13. - 15. October 2020DAY 1 start time end time Track 1 (main stage) Track 2 Track 3 Track 4 presentation interaction

8:45 AM 9:00 AM ITHEC Vitual Edition Opening Day 1: Good morning coffee w/ team 159:00 AM 9:05 AM Conference Opening - CONGRESS BREMEN 59:05 AM 9:10 AM Welcome Note - FIBRE / Faserinstitut Bremen 59:10 AM 9:20 AM Special Note: 3D Printing - Composites World 109:20 AM 9:50 AM Keynote 1: Aerospace 20 10

9:50 AM 10:15 AM Aerospace I - 1 Emerging Technologies I - 1 Automotive I - 1 20 510:15 AM 10:40 AM Aerospace I - 2 Emerging Technologies I - 2 Automotive I - 2 20 510:40 AM 11:05 AM Aerospace I - 3 Emerging Technologies I - 3 Automotive I - 3 20 5

live networking & break-out sessions: sessions a 20 min. in 3 parallel tracks:11:10 AM 11:30 AM Business Speed Dating #1 Industry Break-Out session #1 Industry Break-Out session #2 Industry Break-Out session #3 20

11:35 AM 12:00 PM Aerospace I - 4 Emerging Technologies I - 4 Automotive I - 4 20 512:00 PM 12:25 PM Aerospace I - 5 Emerging Technologies I - 5 Automotive I - 5 20 5

live networking & break-out sessions: sessions a 20 min. in 3 parallel tracks:12:35 PM 12:55 PM Business Speed Dating #2 Industry Break-Out session #4 Industry Break-Out session #5 Industry Break-Out session #6 20

1:00 PM 1:15 PM JEC Best Paper Award 15155 90

1:30 PM 2:00 PM Live demo / Masterclass / Virtual Round Table #1 (topic t.b.a.) 302:00 PM 2:30 PM Live demo / Masterclass / Virtual Round Table #2 (topic t.b.a.) 30

60 0

2:45 PM 3:00 PM ITHEC Vitual Edition Opening Day 1: Good morning coffee w/ team 153:00 PM 3:05 PM Conference Opening - CONGRESS BREMEN 53:05 PM 3:10 PM Welcome Note - FIBRE / Faserinstitut Bremen 53:10 PM 3:20 PM Special Note: 3D Printing - Composites World 103:20 PM 3:50 PM Keynote 1: Aerospace 20 10

3:50 PM 4:15 PM Aerospace I - 1 Emerging Technologies I - 1 Automotive I - 1 20 54:15 PM 4:40 PM Aerospace I - 2 Emerging Technologies I - 2 Automotive I - 2 20 54:40 PM 5:05 PM Aerospace I - 3 Emerging Technologies I - 3 Automotive I - 3 20 5

live networking & break-out sessions: sessions a 20 min. in 3 parallel tracks5:10 PM 5:30 PM Business Speed Dating #3 Industry Break-Out session #7 Industry Break-Out session #8 Industry Break-Out session #9 20

5:35 AM 6:00 PM Aerospace I - 4 Emerging Technologies I - 4 Automotive I - 4 20 56:00 PM 6:25 AM Aerospace I - 5 Emerging Technologies I - 5 Automotive I - 5 20 5


7:00 PM 7:15 PM JEC Best Paper Award 15155 90

Sum minutes day 1 370 180

Day 1 - Time zones Asia to Europe

Day 1 - European time zone

Day 1 - Time zones The

Americas to Europe

DAY 2 start time end time Track 1 (main stage) Track 2 Track 3 Track 4 Track 5 presentation interaction8:45 AM 9:00 AM ITHEC Vitual Edition Opening Day 2: Good morning coffee w/ team 159:00 AM 9:05 AM Conference Opening - CONGRESS BREMEN 59:05 AM 9:35 AM Keynote 2: Automotive 20 10

9:35 AM 10:00 AM Aerospace II - 1 Emerging Technologies II - 1 Automotive II - 1 20 510:00 AM 10:25 AM Aerospace II - 2 Emerging Technologies II - 2 Automotive II - 2 20 510:25 AM 10:50 AM Aerospace II - 3 Emerging Technologies II - 3 Automotive II - 3 20 5

live networking & break-out sessions: sessions a 20 min. in 3 parallel tracks10:55 AM 11:15 AM Business Speed Dating #5 Industry Break-Out session #13 Industry Break-Out session #14 Industry Break-Out session #15 20

11:20 AM 11:45 AM Aerospace II - 4 Emerging Technologies II - 4 Automotive II - 4 20 511:45 AM 12:10 PM Aerospace II - 5 Emerging Technologies II - 5 Automotive II - 5 20 5


Poster Session Breakouts - 4 parallel tracks a 10 minutes12:40 PM 12:50 PM Poster 1 Poster 2 Poster 3 Poster 4 1012:50 PM 1:00 PM Poster 5 Poster 6 Poster 7 10

1:00 PM 1:10 PM Poster 8 Poster 9 Poster 10 101:10 PM 1:20 PM Poster 11 Poster 12 Poster 13 10

125 130


30 45

2:45 PM 3:00 PM ITHEC Vitual Edition Opening Day 2: Good morning coffee w/ team 153:00 PM 3:05 PM Conference Opening - CONGRESS BREMEN 53:05 PM 3:35 PM Keynote 2: Automotive 20 10

3:35 PM 4:00 PM Aerospace II - 1 Emerging Technologies II - 1 Automotive II - 1 20 54:00 PM 4:25 PM Aerospace II - 2 Emerging Technologies II - 2 Automotive II - 2 20 54:25 PM 4:50 PM Aerospace II - 3 Emerging Technologies II - 3 Automotive II - 3 20 5


5:20 PM 5:45 PM Aerospace II - 4 Emerging Technologies II - 4 Automotive II - 4 20 55:45 PM 6:10 PM Aerospace II - 5 Emerging Technologies II - 5 Automotive II - 5 20 5


Poster Session Breakouts - 4 parallel tracks a 10 minutes6:40 PM 6:50 PM Poster 14 Poster 15 Poster 16 106:50 PM 7:00 PM Poster 17 Poster 18 Poster 19 107:00 PM 7:10 PM Poster 20 Poster 21 Poster 22 107:10 PM 7:20 PM Poster 23 Poster 24 Poster 25

125 120Sum minutes day 2 280 295




Americas to Europe

DAY 3 start time end time Track 1 (main stage) Track 2 Track 3 Track 4 presentation interaction8:45 AM 9:00 AM ITHEC Vitual Edition Opening Day 3: Good morning coffee w/ team 159:00 AM 9:05 AM Conference Opening - CONGRESS BREMEN 59:05 AM 9:35 AM Keynote 3: 3D Printing 20 10

9:35 AM 10:00 AM Aerospace III - 1 (Welding) Emerging Technologies III - 1 (3D-Printing) 20 510:00 AM 10:25 AM Aerospace III - 2 (Welding) Emerging Technologies III - 2 (3D-Printing) 20 510:25 AM 10:50 AM Aerospace III - 3 (Welding) Emerging Technologies III - 3 (3D-Printing) 20 5

live networking & break-out sessions: sessions a 20 min. in 3 parallel tracks10:55 AM 11:15 AM Business Speed Dating #9 Industry Break-Out session #25 Industry Break-Out session #26 Industry Break-Out session #27 20

11:20 AM 11:45 AM Aerospace III - 4 (Welding) Emerging Technologies III - 4 (3D-Printing) 20 511:45 AM 12:10 PM Aerospace III - 5 (Welding) Emerging Technologies III - 5 (3D-Printing) 20 5

12:15 PM 1:15 PM Panel discussion: 3D Printing 30 301:15 PM 1:30 PM NEW: ITHEC Best Poster Award 15

170 85


30 45

2:45 PM 3:00 PM ITHEC Vitual Edition Opening Day 3: Good morning coffee w/ team3:00 PM 3:05 PM Conference Opening - CONGRESS BREMEN 53:05 PM 3:35 PM Keynote 3: 3D Printing 20 10

3:35 PM 4:00 PM Aerospace III - 1 (Welding) Emerging Technologies III - 1 (3D-Printing) 20 54:00 PM 4:25 PM Aerospace III - 2 (Welding) Emerging Technologies III - 2 (3D-Printing) 20 54:25 PM 4:50 PM Aerospace III - 3 (Welding) Emerging Technologies III - 3 (3D-Printing) 20 5


5:20 PM 5:45 PM Aerospace III - 4 (Welding) Emerging Technologies III - 4 (3D-Printing) 20 55:45 PM 6:10 PM Aerospace III - 5 (Welding) Emerging Technologies III - 5 (3D-Printing) 20 5

6:15 PM 7:15 PM Panel discussion: 3D Printing 30 307:15 PM 7:30 PM NEW: ITHEC Best Poster Award 15

170 85Sum minutes day 3 370 215

SUM minutes ITHEC 1020 690SUM hours ITHEC 17,00 11,50




Americas to Europe

4

Session "Aerospace I" ....................................................................................... 8

1: Formation of in-plane Waviness in Thermoplastic Composite Laminate Consolidation .............................................................................................................. 8

2: Interface Properties & Improvements in Overmoulded Composites ................. 8

3: Application of Lightning Strike Protection on Thermoplastic Structures by Automated Fiber Placement ....................................................................................... 9

4: Increasing the Performance of CCM Technology ............................................. 9

5: Post Flight Analysis of an in situ Consolidated Thermoplastic Rocket Module with Integrated Fiber Optic Temperature Sensors .................................................... 10

Session "Emerging Technologies I" ........................................................... 11

1: Qualification of Unidirectional Carbon Fiber Reinforced PA12 Material for the Use in Thermoplastic Composite Pipes .................................................................... 11

2: Development of a Structural Subframe for a Battery Electric Vehicle using Continuous Fibre Reinforced Thermoplastics ........................................................... 11

3: Optimised Design for Hybrid Structural Thermoplastic Composite Part .......... 12

4: Natural Fibre Reinforced Bioplastics for Use in High Performance Structural Parts 12

5: Difficulties on Testing Fibre Reinforced Thermoplastic ................................... 13

Session „Automotive I“ ................................................................................... 14

1: Manufacturing of an Automotive Rear Seat Structure with one Shot Hybrid Thermoplastic Composites ....................................................................................... 14

2: ARWeS – Automatic Roving Changing System for Continuous Textile Processes ................................................................................................................. 14

3: Tailor-made Thermoplastic Rods and Application in Winding ......................... 15

4: Methodology for Material Selection in Skeleton Design .................................. 15

5: Online Analysis of Geometrical Inaccuracies During the in-situ Automated Fiber Placement of Tailored Composite Blanks out of Thermoplastic Tape ............. 16

Session „Aerospace II“ ................................................................................... 17

1: T - Profile with Effective Lay-up in one Shot ................................................... 17

2: Out of Autoclave Consolidation of Fiber Placed Thermoplastic Composite Structures ................................................................................................................. 18

3: The Influence of Material and Blank on Rapid Fabrication of Continuous Fiber Reinforced Thermoplastic Composites ..................................................................... 18

4: High speed thermoplastic tape placement with CoRe HeaT ........................... 19

5: Development of a Sandwich Panel with Carbon Fiber-reinforced Thermoplastic Skins 19

5

Session "Emerging Technologies II" .......................................................... 20

1: Laser-assisted Tape Placement with in-situ Consolidation for the Production of Thermoplastic Tailored Blanks – 2 new Machine System Innovations from Aachen 20

2: High-precision Stacking of Thermoplastic Composite Tapes using Image Processing ................................................................................................................ 20

3: A Review of the A+ Glide Forming Manufacturing Process and its Adaptation to CFRP Thermoplastic Composite Materials ............................................................... 21

4: Thermoplastic Fiber - Metal Laminates for Automated Production ................. 21

5: Impact Modification of CF / PPS with Functional Fluoropolymers ................... 22

Session "Automotive II" .................................................................................. 23

1: Integrated Process Simulation as Key for the Efficient Product and Process Development ............................................................................................................ 23

2: Process and Bonding Modification for Media-based Forming of Complex Continuous Fiber Reinforced Hybrid Parts ............................................................... 24

3: Experimental Study and Numerical Simulation of Interface Failure of Injection over-molded Thermoplastic Composites .................................................................. 24

4: The “Digital Friend”: Towards a Sensor-supported Simulation and the Establishment of a new Thermoplastic C-RTM Process with Caprolactam .............. 25

5: Simulation of Thermoforming Process of Thermoplastic based Sandwich Laminates made of Cross-ply and Honeycomb Core ............................................... 26

Session "Automotive III: Welding" .............................................................. 27

1: Process Data Driven Advancement of Robot-based Continuous Ultrasonic Welding for the Dust-free Assembly of Future Fuselage Structures ......................... 27

2: Recent Developments in Ultrasonic Welding of Epoxy- to Thermoplastic-based Composites ............................................................................................................... 27

3: Resistance Welding Simulation through Application and Modification of Crystallisation Models ............................................................................................... 28

4: Industrialisation Aspects for Ultrasonic Welding of Large Thermoplastic Aerospace Structures ............................................................................................... 29

5: Focused Inductive Heat Generation in Weld Zones of Carbon Fibre Laminates by Magnetic Field Manipulation and Carbon Fibre Susceptors ................................. 29

Session "Emerging Technologies III: 3D Printing" ................................ 30

1: New Technique for Impregnating Rovings with High Viscous Melts ............... 30

2: Characterization of Additively Manufactured Endless Fiber Reinforced Multi-material Composites ................................................................................................. 30

3: Seamless Solution for Industrial-grade Continuous Carbon Fibre 3D-printed Composites ............................................................................................................... 31

4: Development of a Test Bench for Fused Filament Fabrication ....................... 31

6

5: Large Scale 3D Printed Thermoplastic Composite Forms for Precast Concrete Structures ................................................................................................................. 32

Poster .................................................................................................................... 33

Poster 01: CAE Tools for Overmoulded Thermoplastic Composites – State-of-the-art and Future Developments ........................................................................................ 33

Poster 02: Out-of-autoclave Manufacturing of Thermoplastic Fuselage Skins with Integrated Stringers .................................................................................................. 34

Poster 03: Evaluation on Rivet Fastening by Ultra-compact Servo Press Thermoforming ......................................................................................................... 34

Poster 04: The Investigation of Advanced Thermoplastic Composite Materials in Aerospace Applications ............................................................................................ 35

Poster 05: Investigation of Material Extrusion based Print Heads for Thermoplastic Composites by Internal Pressure Analysis ............................................................... 35

Poster 06: eVTOL Fan Casing with Integral Stiffeners and Attachment Points ........ 36

Poster 07: Welding of UD Carbon LM-PAEK and PEKK Tapes ............................... 36

Poster 08: Experimental and Numerical Research of the MM Welding® Joining Technology for Sandwich Panels ............................................................................. 37

Poster 09: Polyamide 6 Carbon Fiber Composites obtained by T-RTM: Thermal, Chemical and Mechanical Characterization .............................................................. 38

Poster 10: Towards an Increased Reliability of Resistance Welded Joints for Aircraft Assembly .................................................................................................................. 38

Poster 11: ConThP: Consolidation of Thermoplastic Hybrid Yarn Materials ............. 39

Poster 12: Density Influence on the Formation of Skin Layers in Integral Sandwich Structures based on Open Pore PESU Foams ......................................................... 39

Poster 13: Development of High Cycle Rivet Fastening Process by Ultra-compact Servo Press Machine using Unidirectional CFRTP Rivet ......................................... 40

Poster 14: Mechanical Properties of Carbon-Fiber Thermoplastic Composites Manufactured by Laser Assisted Fiber Placement (LAFP) ....................................... 40

Poster 15: Consolidation Behavior of Fiber Steered Thermoplastic Automated Fiber Placement Preforms ................................................................................................. 41

Poster 16: Resistance Welding of Primary Aircraft Structures .................................. 42

Poster 17: Efficient Determination of Material Parameters for Robust Process Simulation of Semi-crystalline Thermoplastic Composites ....................................... 42

Poster 18: Applying Digital Twin Technology in Thermoplastic Composites Production ................................................................................................................................. 43

Poster 19: Plasma Treatment of Carbon Fiber for Extrusion Based Additively Manufactured Thermoplastic Composites” ............................................................... 44

Poster 20: Laser Drilling of CFRP for Aerospace Applications – High Quality and yet Fast?......................................................................................................................... 44

7

Poster 21: Multiaxial Thermoplastic Prepregs - Assessment of Manufacturing Strategies with Focus on Fiber Laying, Spreading and Impregnation ....................... 45

Poster 22: New Trends and Standards in the Tailored Blank Manufacturing ............ 46

Poster 23: Improved Quality of Nonwovens made from Recycled Carbon Fibres by Processing Line with on-line Control of Wear Level ................................................. 46

Poster 24: Simulation of the VCSEL-Assisted In Situ Tape Placement Process ...... 47

Poster 25: Closed-form Solutions for Spring-in Prediction in Thermoplastic Forming 48

8

Session "Aerospace I" Session Chairs: A. Blom-Schieber / I. Fernandez Villegas

1: Formation of in-plane Waviness in Thermoplastic Composite Laminate Consolidation E. Krämer, ThermoPlastic composites Research Center, Enschede, Netherlands, and University of Twente, Enschede, Netherlands W. Grouve, University of Twente, Enschede, Netherlands L. Warnet, University of Twente, Enschede, Netherlands S. Koussios, ThermoPlastic composites Research Center, Enschede, Netherlands R. Akkerman, University of Twente, Enschede, Netherlands, and ThermoPlastic composites Research Center, Enschede, Netherlands

Abstract: Keywords: It is desirable to prevent or minimize fiber waviness during manufacturing of thermoplastic composite parts, as this nonconformity causes a knockdown in the mechanical performance. The possible mechanisms for waviness formation have been identified experimentally: axial compressive forces caused by tool shrinkage, transverse flow of the material and deconsolidation, caused by moisture release and residual stresses. The prominent mechanisms have been incorporated in a descriptive model for the formation of in-plane waviness during the consolidation of C/PEEK laminates. The model gives insight into the sensitivity of the processing parameters and will aid in determining manufacturing guidelines for waviness-free laminates.

Thermoplastic Composites, Waviness, Modelling, C/PEEK

2: Interface Properties & Improvements in Overmoulded Composites S. Ivan, Victrex, Thornton Cleveleys, United Kingdom S. Green, Victrex, Thornton Cleveleys, United Kingdom F. Ferfecki, Victrex USA, West Conshohocken, United States

Abstract: Keywords: As overmoulding technology continues to gain credibility for delivering high volume aerospace quality parts, Victrex is investigating the effect of the interface bond on part performance. When evaluating the mechanical performance of hybrid composite elements, onset failure typically occurs at the interface between the materials. To characterise interface performance, mechanical testing is being conducted to ascertain the impact of a variety of interface types based on existing VICTREX™ PEEK and PAEK polymers.

Overmould, Overmoulding, Hybrid Composite, PEEK, PAEK, Polyaryletherketone

9

3: Application of Lightning Strike Protection on Thermoplastic Structures by Automated Fiber Placement C. Nguyen, DLR e. V., Stade, Germany A. Kolbe, DLR e. V., Stade, Germany C. Bäns, DLR e. V., Stade, Germany

Abstract: Keywords: The application of Lightning Strike Protection (LSP) material on the outer surface of a carbon fibre reinforced thermoplastic part with Automated Fiber Placement (AFP) had been analysed. Beside the development of a hybrid LSP material, which fulfils the requirements of an AFP process, automated layup trials with Xenon heating flash lamp had been realised to determine capable process parameters. Furthermore, test specimens with different layup designs and material combinations had been manufactured and their electrical properties had been investigated. The fundamental trials presented in this paper demonstrate the feasibility of the integration of a LSP layer using AFP.

Lightning Strike Protection, Automated Fiber Placement, Expanded Copper Foil, Perforated Copper Foil, Thermoplastic, Xenon Flash Lamp

4: Increasing the Performance of CCM Technology F. Piott, Neue Materialien Fürth GmbH, Fürth, Germany A. Lück, Neue Materialien Fürth GmbH, Fürth, Germany L. Hoffmann, Neue Materialien Fürth GmbH, Fürth, Germany D. Drummer, Universität Erlangen-Nürnberg, Erlangen, Germany

Abstract: Keywords: Continuous compression molding technology (CCM) is an economically and technically efficient process for manufacturing organic sheets. The semi-finished products are fully impregnated and consolidated and can be converted into complex 3D-geometries by a thermoforming process in short cycle times. Actual problems of the CCM-process are the slow production speed and optical defects or shrinkage vacuoles due to pressure losses in the laminate. With the integration of an active adaptive pressing tool and an in-line pressure measurement system the CCM-technology can be optimized. With the developed system, the production speed can be accelerated and the quality improved.

Continous Compression Molding, Organic Sheet, Impregnation

10

5: Post Flight Analysis of an in situ Consolidated Thermoplastic Rocket Module with Integrated Fiber Optic Temperature Sensors R. Engelhardt, Technische Universität München, Garching, Germany S. Ehard, Airbus Group, Manching, Germany R. Jemmali, DLR e. V., Stuttgart, Germany J. Oelhafen, fos4X GmbH, München, Germany A. Kollmansberger, Technische Universität München, Garching, Germany K. Drechsler, Technische Universität München, Garching, Germany

Abstract: Keywords: As part of a high-altitude research rocket mission, the Chair of Carbon Composites of Technical University Munich developed and implemented a manufacturing concept for a thermoplastic fiber composite module of a high-altitude research rocket. In the manufacturing concept, the Automated Fiber Placement process is combined with press-formed long-fiber-reinforced thermoplastic structures. The AFP-laminate and its joint to the LFT-structure is realized by in situ consolidation. The developed module is more than 40% lighter than the conventional aluminum modules and was launched in March 2019 as a structural part of the REXUS-23 rocket at an altitude of 75.42 km. The rocket had a “hard landing” as the main parachute did not open properly which led to considerable additional loads. The module was analyzed via computer tomography to investigate flight- or impact-induced defects. The concept was able to prove its airworthiness being the first in situ consolidated structural component of a rocket mission.

Automated Fiber Placement, In Situ Consolidation, Rocket, Computer Tomography, Aerospace

11

Session "Emerging Technologies I"

Session Chairs: P. Hansen / K. Uzawa

1: Qualification of Unidirectional Carbon Fiber Reinforced PA12 Material for the Use in Thermoplastic Composite Pipes A. Brack, Evonik Resource Efficiency, Marl, Germany C. Schütt, Evonik Resource Efficiency, Marl, Germany A. Paternoster, Airborne Oil & Gas, IJmuiden, Netherlands

Abstract: Keywords: Thermoplastic Composite Pipes (TCP) are offshore pipeline systems that are completely made from polymer materials, using unidirectional fiber-reinforced tapes (UD-tapes) for the structural part to achieve highest mechanical properties and superior lightweight potential. In close collaboration of Airborne Oil & Gas and Evonik Resource Efficiency, a TCP made from carbon-fiber reinforced PA12 material was qualified for the use in static and dynamic offshore applications up to a maximum operating temperature of 80 °C for water injection, hydrocarbons and sour service fluids. Within this paper, the qualification method, the procedure and the results according to DNVGL-ST-F119 will be described, including mechanical tests of the composite material as well as the liner and cover material in dry state at different temperatures, after physical impact by saturation in a reference production fluid and after chemical ageing after the simulated use of 30 years in sour (H2S-containing) service.

Thermoplastic Composite Pipe, Oil&Gas, PA12, Polyamide, UD-Tapes, Material Qualification

2: Development of a Structural Subframe for a Battery Electric Vehicle using Continuous Fibre Reinforced Thermoplastics S. Iwan, thermoPre GmbH, Chemnitz, Germany S. Schneider, Mahle International GmbH, Stuttgart, Germany T. Timmel, thermoPre GmbH, Chemnitz, Germany W. Nendel, Technische Universität Chemnitz, Chemnitz, Germany

Abstract: Keywords: Within the scope of a joint development project between MAHLE International GmbH, Chemnitz University of Technology and thermoPre Engineering GmbH a holistic development of a new subframe for usage in a battery electric vehicle was developed. The result of this development process is a new type of structural components made of long and continuous fibre reinforced plastics. The newly developed subframe achieves the same static performance and cost-neutral production despite the significant mass saving of 33% compared to the reference part made of steel.

Lightweight Design, Continuous Fibre Reinforced Thermoplastics, Battery Electric Vehicle

12

3: Optimised Design for Hybrid Structural Thermoplastic Composite Part Y. Becker, Institut für Verbundwerkstoffe GmbH, Kaiserslautern, Germany N. Motsch-Eichmann, Institut für Verbundwerkstoffe GmbH, Kaiserslautern, Germany J. Hausmann, Institut für Verbundwerkstoffe GmbH, Kaiserslautern, Germany U. Breuer, Institut für Verbundwerkstoffe GmbH, Kaiserslautern, Germany

Abstract: Keywords: Thermoplastic composite parts (TPCs) can show distinct advantages compared to their thermoset counterparts (e. g. short cycle times, easy recycling, remeltabilty). However, a significant market penetration of structural TPC applications is still lacking. This study aims at solving this issue by the combination of discontinuous fibre reinforced injection moulding material and locally used endless fibre reinforced material. With this approach, the advantages of the injection moulding process can be combined with the excellent structural mechanical properties of endless fibre reinforced TPCs.

Hybrid Structure, Thermoplastic Composites, Topology Optimisation

4: Natural Fibre Reinforced Bioplastics for Use in High Performance Structural Parts S. Heßner, Evonik Nutrition & Care GmbH, Essen, Germany K. Lehmann, Evonik Nutrition & Care GmbH, Essen, Germany I. Jahn, Fraunhofer IMWS, Schkopau, Germany M. Zscheyge, Fraunhofer IMWS, Schkopau, Germany R. Rinberg, Technische Universität Chemnitz, Chemnitz, Germany S. Buschbeck, Technische Universität Chemnitz, Chemnitz, Germany M. Begert, EDAG Engineering GmbH, Fulda, Germany T. Brückner, SachsenLeinen GmbH, Markkleeberg, Germany L. Kneisel, SachsenLeinen GmbH, Markkleeberg, Germany

Abstract: Keywords: In future composites based on a biopolymer matrix and continuous natural fibre reinforcement (Bio-NFC) are also to be used for lightweight structure-components that can withstand high stresses at low weight and guarantee stability. Using the example of a child safety seat as demonstrator structure, the possibilities offered by the newly developed materials, technologies and component design concepts for natural fibre reinforced biopolymers will be illustrated. The material development provides a compound, with highest mechanical properties even at thin wall thicknesses. Locally improved mechanical properties are gained by inserting a reinforcing UD-tape. An electron beam crosslinking of the thermoplastic biopolymer is investigated to reach thermoset-specific properties. The adjustment of processing technology allows a processing of flax fibres to a quasi-endless reinforced UD-tapes. At least an appropriate part and mould design for the NFC seat shell guarantees the uniting of the developed materials.

Biopolymer, Natural Fibre, WPC, Tape, Laminate, E-Beam, Hybrid Injection Moulding

13

5: Difficulties on Testing Fibre Reinforced Thermoplastic N. Klemm-Zhao, IMA Materialforschung und Anwendungstechnik GmbH, Dresden, Germany F. Wolf, IMA Materialforschung und Anwendungstechnik GmbH, Dresden, Germany

Abstract: Keywords: Thermoplastic fibre reinforced plastics gained increasingly interest for industry due to its short process time and recycling advantage. For material qualification testing bonding application is often required. End tabs bonding and strain gauges bonding require a secure bonding on specimens. However thermoplastic shows difficulties on chemically bonding due to inherent non-polar property of thermoplastic. For fibre reinforced thermoplastics, however, it often occurs that end tabs fall off from specimens causing mechanical testing impossible. The purpose of this work is to find out optimal surface treatments for bonding fibre reinforced thermoplastics. Glass fibre and carbon fibre reinforced thermoplastics under different treatments are studied.

Testing, Fibre Reinforced Thermoplastic, Surface Treatment

14

Session „Automotive I“

Session Chairs: M. Würtele / P. Mitschang

1: Manufacturing of an Automotive Rear Seat Structure with one Shot Hybrid Thermoplastic Composites T. Renault, Faurecia Zero Emissions, Saint Malo, France S. Guéroult, IRT Jules Verne, Bouguenais, France

Abstract: Keywords: An automotive rear seat structure is developed and manufactured with the one shot hybrid thermoplastic composite technology that combines the use of organo sheet as a backbone, back-injected short fibre compounds, and metal inserts. The part replaces an assembly of nine metal parts to yield a net shape complex part with high function integration and a manufacturing process that is fully automated. The organo sheet backbone is made of 5 organo patches with various fibre orientation and thickness to optimize the part weight and cost. The conference will describe the design of the part, the selection of materials and implementation of the process as well as the results of the part validation.

Organo Sheet, Hybrid Thermoplastic Composite, Seat

2: ARWeS – Automatic Roving Changing System for Continuous Textile Processes S. Nendel*, Cetex Institut gGmbH, Chemnitz, Germany F. Mehlhorn, Cetex Institut gGmbH, Chemnitz, Germany

Abstract: Keywords: For the use of fiber-plastic composite applications (FRP), the continuous and large-scale production of continuous fiber-reinforced semi-finished products is absolutely necessary. The process management in the individual sub-aspects must run uninterruptedly. Especially in UD tape production processes are interrupted to perform a material change. The resulting downtimes lead to enormous costs in terms of personnel and non-existent process utilization. For this reason, a new system technology for automatic roving change has been developed at the Cetex Institute, which makes it possible to carry out material changes while the machine is running at reduced machine speed. This ensures a 24/7 operation of the plants and thus significantly increases the output. The innovative system can be used for all available reinforcement fiber systems (glass, basalt, carbon). The new solution enables fully automatic plant operation without interruption and the reproducible connection of the reinforcing fibers with each other.

Automation, Roving Change, UD Tape, Organic Sheet, FRP, 24/7 Operation,

15

3: Tailor-made Thermoplastic Rods and Application in Winding M. Holzinger, SGL Technologies GmbH, Meitingen, Germany M. Gruber, SGL Technologies GmbH, Meitingen, Germany C. Loy, SGL Technologies GmbH, Meitingen, Germany V.P. Brudzinski, SGL Technologies GmbH, Meitingen, Germany V. Bühler, SGL Technologies GmbH, Meitingen, Germany

Abstract: Keywords: Tailor-made thermoplastic rods are the latest development for the thermoplastic-based product portfolio of SGL Carbon. A rod represents a 50k carbon fiber roving impregnated with thermoplastic matrices. The shape of the rods can be individually adjusted. Through continuous winding on spools they represent an ideal base material for additive manufacturing. The potential of the rods is illustrated in an application demonstrator, which is manufactured by winding.

Carbon Fiber, Rods, CFRTP, Winding, Light Weight Design

4: Methodology for Material Selection in Skeleton Design A. Maier, BMW Group, München, Germany L. Kroll, Technische Universität Chemnitz, Chemnitz, Germany

Abstract: Keywords: A tailored use of continuous fiber reinforced plastics is the key to economic lightweight design. For optimal usage of anisotropic mechanical properties, the design must be changed from sheet to profile base. Furthermore, thermoplastic matrices offer huge advantages compared to thermoset matrices regarding e. g. cycle time and recyclability. A design taking those advantages is the so called “skeleton design”. Within this design unidirectional, continuous, fiber reinforced thermoplastic (CFRTP) profiles are combined with injection molding. The CFRTP profiles are placed in the load paths of the part in order to ensure the mechanical performance. Injection molding is responsible for shear force transmission as well as assembling the structure. In order to give an indication if a material offers economic potential compared to another a new index based on material indices by Ashby and lightweight costs (lwc) is derived. Glass fibers offer huge potential regarding material costs whereas its density is higher compared to carbon fibers. The indices are derived for the main loading conditions tension, compression, bending and shear for unidirectional thermoplastic composites. The relative mechanical properties are derived for pultruded carbon and glass as well as carbon/glass hybrid fiber reinforced polyamide 6 (PA6). It is shown that glass fiber reinforced thermoplastics (gfrtp) offer potential for strength dominated profiles under compression, bending and shear loading regarding weight and costs. The application of this approach is discussed with focus on windshield panel developed within MAI SKELETT research project.

Carbon Fibers, Glass Fibers, Thermoplastic Resin, Mechanical Testing, Material Selection

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5: Online Analysis of Geometrical Inaccuracies During the in-situ Automated Fiber Placement of Tailored Composite Blanks out of Thermoplastic Tape M. Schulz, Fraunhofer IPT, Aachen, Germany H. Janssen, Fraunhofer IPT, Aachen, Germany C. Brecher, Fraunhofer IPT, Aachen, Germany

Abstract: Keywords: In the case of composite materials, data acquisition and analytics can enable the attractiveness on the market by simplifying process knowledge and increasing production robustness. This leads to less setup times and also less material waste. The in-situ automated fiber placement (AFP) of thermoplastic tape offers high potential to be a suitable production technology for the automatized manufacture of composite parts. This study focuses on the use of online metrology to capture geometrical insufficiencies during the AFP process of tailored composite blanks. These insufficiencies account for layup defects, for example gaps or overlaps, indicating either process or system inaccuracies. Along a standardized methodology, this study selects, implements and validates the use of sensors for acquiring a relevant data base and to enable a digital shadow for visualizing geometrical defects. By acquiring this data further correlations between process and part quality can be drawn and an online evaluation is possible.

Automated Fiber Placement, Thermoplastic Composite, Industrie 4.0, Quality Control

17

Session „Aerospace II“

Session Chairs: A. Blom-Schieber / I. Fernandez Villegas

1: T - Profile with Effective Lay-up in one Shot J. Křena, Latecoere Czech Republic, Prague, Czech Republic Z. Padovec, Czech Technical University, Prague, Czech Republic R. Sedlacek, Czech Technical University, Prague, Czech Republic T. Zamecnikova, Czech Technical University, Prague, Czech Republic

Abstract: Keywords: T-profile is part, which is frequently used in structural assembly. It is suitable for loading but difficult for thermoforming. Innovation is included in the very quick process of manufacturing and in addition in the achieved inner optimal structure of T-profile. Reinforced thermoplastic carbon fabric with PPS matrix in the form of consolidated plate was used for manufacturing of the part. The invention is included in the special manipulation of the blank in collaboration with the special stamping tool with the moving elements, which create final shape of the profile in one stamping step. The process is dramatically shorter than state of the art of the similar part manufacturing. That process creates optimal placement of layers what provides very good mechanical performance. The advantage is that the core/intersection of profile don´t need any additional material, which is normally used to fill “Bermuda triangle”. It is given by the special profile shape and process forming. The stress analysis was carried out by FEM for typical load of such part. The results were compared with the mechanical test. Modified profile with Y shape seems to be more effective what was confirmed both analysis and mechanical test. The stiffness and behavior after first crack is better for that modified profile.

T - Profile, Thermoforming

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2: Out of Autoclave Consolidation of Fiber Placed Thermoplastic Composite Structures J. Narayana Swamy, ThermoPlastic composites Research Center, Enschede, Netherlands, and University of Twente, Enschede, Netherlands L. Niens, University of Twente, Enschede, Netherlands S. Wijskamp, ThermoPlastic composites Research Center (TPRC), Enschede, Netherlands W. Grouve, University of Twente, Enschede, Netherlands R. Akkerman, University of Twente, Enschede, Netherlands

Abstract: Keywords: The two most obvious manufacturing technologies for larger primary aircraft structures are autoclave consolidation and in-situ automated fiber placement (AFP). However, the former requires expensive tooling and is limited by autoclave size, while the latter to date still lacks maturity. Therefore, the industry is currently banking on a two-step approach involving the automated deposition of pre-impregnated tape using AFP, followed by an out-of-autoclave consolidation step, for example, Vacuum Bag Only (VBO) consolidation. In this work, a method is presented to achieve void-free consolidation of AFP + VBO processed thermoplastic composites.

Out-of-Autoclave, Voids, Automated Fiber Placement, Thermoplastic Composites

3: The Influence of Material and Blank on Rapid Fabrication of Continuous Fiber Reinforced Thermoplastic Composites D. Leach, ATC Manufacturing, Post Falls, USA T. McCrea, ATC Manufacturing, Post Falls, United States R. Postera, ATC Manufacturing, Post Falls, USA

Abstract: Keywords: The influence of material and blank consolidation on the quality of a continuous fiber reinforced thermoplastic stamp formed structural part have been evaluated. A complex curvature part was fabricated with two PEKK/carbon fiber unidirectional (CFUD) tapes with different characteristics. The effects of the degree of blank consolidation were assessed for PEEK/CFUD tapes. Experimental results have been compared with those from forming models. Results will be presented showing the effect of material differences and blank consolidation on fabrication characteristics and quality of the finished part.

Thermoplastic, Composites, Process, Stamp Forming, Modeling

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4: High speed thermoplastic tape placement with CoRe HeaT Y. Grohmann, DLR e. V., Stade, Germany

Abstract: Keywords: CoRe HeaT, the Continuous Resistance Heating Technology, is an alternative to state-of-the-art heating systems for carbon fibre placement processes like the Automated Fibre Placement method (AFP) or filament winding. Basic principle of the technology is using the Joule effect to heat up carbon fibres intrinsically via their own resistance. This leads to improved energy efficiency and heating rates, allowing significantly faster placement compared to today's technology, enabling increased productivity for a variety of manufacturing processes.

Heating Technology, Automated Fibre Placement (AFP), Manufacturing Process

5: Development of a Sandwich Panel with Carbon Fiber-reinforced Thermoplastic Skins M. Heim, CNES, Toulouse, France F. Cavalière, Ariane Group, Les Mureaux, France F. Levallois, Airbus Group, Toulouse, France O. Damiano, Thales Alenia Space, Cannes la Bocca, France

Abstract: Keywords: Composite sandwich panels are largely used for structural applications in the space sector, both for launchers (payload adapter, fairing) and satellites (optical benches, antenna reflectors, solar panels). These sandwich panels are mostly composed of an aluminum honeycomb core and thermosetting composite skins. There is currently no sandwich structure with thermoplastic composite skins in space applications, yet the advantages of this type of matrix are numerous: storage at room temperature with no time limitation, low moisture absorption, quick transformation cycle, new assembly opportunities brought by thermoplastic weldability… The objective of this study is to produce and characterize a sandwich panel with carbon fiber-reinforced thermoplastic skins, able to fulfill the requirements of space structures. Therefore a materials and processes trade-off was conducted, sandwich panels were manufactured and charaterization tests were performed both at skin and sandwich levels.

Thermoplastic, Sandwich, Carbon Fiber, Space

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Session "Emerging Technologies II"

Session Chairs: P. Hansen / K. Uzawa

1: Laser-assisted Tape Placement with in-situ Consolidation for the Production of Thermoplastic Tailored Blanks – 2 new Machine System Innovations from Aachen M. Emonts*, Aachener Zentrum für Integrativen Leichtbau, Aachen, Germany and Conbility GmbH, Aachen, Germany K. Fischer, Aachener Zentrum für Integrativen Leichtbau, Aachen, Germany and Conbility GmbH, Aachen, Germany H. Janssen, Fraunhofer IPT, Aachen, Germany A. Peitz, Aachener Zentrum für Integrativen Leichtbau, Aachen, Germany

Abstract: Keywords: Two new key-ready and laser-safe production machines for laser-assisted tape placement with in-situ consolidation will be described in detail within this paper including the achievable consolidation qualities in correlation with process parameters at high production speeds: The table-based laser-assisted tape placement system “PrePro 2D Laser” with a multi-spool tape placement applicator and the “Ultra-Fast Consolidator” machine system realizing cycle times of

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3: A Review of the A+ Glide Forming Manufacturing Process and its Adaptation to CFRP Thermoplastic Composite Materials D. Campos, Applus+ Laboratories, Bellaterra, Spain, and University of Girona, Girona, Spain J. Brufau, Applus+ Laboratories, Bellaterra, Spain M. Biurrun, Applus+ Laboratories, Bellaterra, Spain A. Martín, Applus+ Laboratories, Bellaterra, Spain

Abstract: Keywords: A+ Glide Forming is an automatic manufacturing technology to produce geometrically complex long composite components. A+ Glide Forming guarantees wrinkle-free parts thanks to its inherent features such as the correct flat development of the final surface. Moreover, its continuous nature makes it a high rate process, which is essential to fulfil the production goals of aeronautic industry in the near future. This paper aims to expose not only the evolution of A+ Glide Forming but also the advances in the application of this cutting-edge technology to the new generation of thermoplastic composite materials. Thus, this work intends to prove the technical feasibility of applying this manufacturing method to thermoplastic composite components showing that no post-consolidation process is needed. For this purpose, several geometries, such as T-shape stringers and Z-shape reinforcements, have been tested in Applus+’s demonstrator machine.

Thermoplastic Materials, Automated Manufacturing,  Continuous Process, Glide Forming

4: Thermoplastic Fiber - Metal Laminates for Automated Production F. Schubert, SGL Carbon GmbH, Meitingen, Germany

Abstract: Keywords: A new approach for an innovative hybrid composite material is the laminate combination of aluminum with carbon fiber-reinforced thermoplastics. This offers new potentials regarding mechanical and lightweight properties, recyclability, repairability and reliability for automated series production avoiding contact with hazardous resins and chemicals. Reduced costs and higher flexibility in the manufacturing process open up new applications in the field of individually designed small series.

Fiber-Metal Laminates, FML, Thermoplastic, Automated Production, Hybrid Composite

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5: Impact Modification of CF / PPS with Functional Fluoropolymers T. Hosoda, AGC Inc., Chiba-shi, Japan N. Ozawa, AGC Inc., Chiba-shi, Japan C.-P. Keller*, AGC Chemicals Europe, Amsterdam, Netherlands

Abstract: Keywords: CF/PPS is one of the preferred high performance CFRTP material combinations. However, the industry is seeking for solutions to overcome the brittleness of PPS and improve its overall impact resistance in a composite. This work will show how a functional fluoropolymer can be used as impact modifier for a PPS matrix. Improved stress-to-strain performance as well as better fibre-matrix adhesion have been achieved in these investigations.

Impact Modifier, CF/PPS, Fluoropolymer, Fibre-Matrix Adhesion

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Session "Automotive II"

Session Chairs: M. Würtele / P. Mitschang

1: Integrated Process Simulation as Key for the Efficient Product and Process Development M. Hohberg, SIMUTENCE GmbH, Karlsruhe, Germany, and Karlsruher Institut für Technologie, Karlsruhe, Germany D. Dörr, SIMUTENCE GmbH, Karlsruhe, Germany B. Fengler, SIMUTENCE GmbH, Karlsruhe, Germany, and Karlsruher Institut für Technologie, Karlsruhe, Germany C. Krauß, Karlsruher Institut für Technologie, Karlsruhe, Germany N. Meyer, Karlsruher Institut für Technologie, Karlsruhe, Germany L. Kärger, Karlsruher Institut für Technologie, Karlsruhe, Germany F. Henning, Karlsruher Institut für Technologie, Karlsruhe, Germany, and Fraunhofer-ICT, Pfinztal, Germany

Abstract: Keywords: The integration of process simulation into a holistic virtual process chain enables to accurately predict the part's behavior in terms of dimensional stability and structural performance. Based on this, the knowledge on the manufacturing process and the part’s structural behavior is significantly increased in early development phases. This presentation shows by means of different thermoplastic process routes how manufacturing effects can be predicted and how these can be taken into account in subsequent simulation on basis of a functional virtual process chain.

Process Simulation, Virtual Process Chain, Process Optimization, Enhanced Simulation Methods

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2: Process and Bonding Modification for Media-based Forming of Complex Continuous Fiber Reinforced Hybrid Parts U. Engelmann, Technische Universität Chemnitz, Chemnitz, Germany S. Demmig, Technische Universität Chemnitz, Chemnitz, Germany M. Layer, Technische Universität Chemnitz, Chemnitz, Germany L. Kroll, Technische Universität Chemnitz, Chemnitz, Germany W. Nendel, Technische Universität Chemnitz, Chemnitz, Germany W.-G. Drossel, Fraunhofer IWU, Chemnitz, Germany A. Albert, Fraunhofer IWU, Chemnitz, Germany E. Reese, Daimler AG, Hamburg, Germany T. Harms, Daimler AG, Hamburg, Germany

Abstract: Keywords: This research discribes the modification of combined processes, which merge injection molding and media-based forming to produce lightweight hybrid structures, saving resources compared to separate processes in sequential order. A tube-based process combination of internal high pressure forming, using gas as pressure medium and injection molding, was investigated. Endless fiber reinforced tubes could be processed this way for the first time in a manner suitable for large-scale production. To support the process modification a numerical approach is created. For this purpose, the failure mode concept according to Cuntze was modified for the three-dimensional stress state to analyze possible failure and leakage. The quality of combination is evaluated via bonding strength and compared to metal/polymer hybrids.

Hybrid, Injection Molding, Hydroforming, Bonding Strength, Fibre Reinforced Plastic, Structural Components, Cuntze Criteria

3: Experimental Study and Numerical Simulation of Interface Failure of Injection over-molded Thermoplastic Composites A. Rezaei, TNO/Brightlands Materials Center, Geleen, Netherlands Y. Su, TNO/Brightlands Materials Center, Geleen, Netherlands A. Codou, TNO/Brightlands Materials Center, Geleen, Netherlands M. Huisman, TNO/Brightlands Materials Center, Geleen, Netherlands

Abstract: Keywords: Injection over-molded thermoplastic composites are gaining great attention in different industrial applications. Nevertheless, scientific insight on the topic is limited, and the available knowledge on the design and application of these materials is mainly based on trial and error approaches. Comprehensive studies are essential to analyze the short- and long-term performance of these products. Particularly, characterizing the mechanical behavior of the interface zone between an over-molded component and its counterpart substrate is crucial. This article studies the adhesion bond behavior of injection over-molded glass fiber reinforced thermoplastics. Using an evolved peeling test method, interface failure of the testing materials is experimentally evaluated. The obtained experimental data are then used to create traction

Interface, Over-molding, FEM, Thermoplastic Composites

25

separation models for different failure modes. Finally, from those models, a mixed-mode failure model is derived that can be used in failure prediction of the injection over-molded components with complex geometries and under complex loading conditions.

4: The “Digital Friend”: Towards a Sensor-supported Simulation and the Establishment of a new Thermoplastic C-RTM Process with Caprolactam M. Beyrle, DLR e. V., Augsburg, Germany F. Masseria, Engineering System International GmbH, Neu-Isenburg, Germany J. Faber, DLR e. V., Augsburg, Germany T. Full, DLR e. V., Augsburg, Germany

Abstract: Keywords: Fiber reinforced thermoplastic materials are becoming increasingly interesting for structural components in aerospace and automotive industry due to their beneficial properties (e.g. weldability). In the high-volume production segment, however, this class of materials is in strong competition with established thermoset manufacturing processes such as the Compression Resin Transfer Molding (C-RTM). For this reason, a thermoplastic material system (Caprolactam) is investigated which seems to be suitable for a thermoplastic C-RTM process. In order to gain a better understanding of this novel process in which Caprolactam polymerizes with an activator and a catalyst under pressure and increased temperature to Polyamide 6 (PA6), the press tool was equipped with an array of different sensors. In addition to the physical experiments, a simulation of the C-RTM process was set up in ESI PAM-COMPOSITES (PAM-RTM module). The C-RTM process with glass fiber nonwoven fabric is a novelty, especially because of low compaction of the elimination of the gap. For the simulation modelling of this special C-RTM set-up with nonwoven fabrics, a process-specific extension of the software was developed and implemented in the graphical user interface release version Visual-RTM 15.5. Finally, the results of the simulation were compared with those of the real experiments.

Thermoplastic, C-RTM, Simulation, Caprolactam, PA6, Inline Process Control, Sensors

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5: Simulation of Thermoforming Process of Thermoplastic based Sandwich Laminates made of Cross-ply and Honeycomb Core V.K. Minupala, Fraunhofer IMWS, Schkopau, Germany, and Fraunhofer PAZ, Schkopau, Germany T. Gläßer, Fraunhofer IMWS, Schkopau, Germany, and Fraunhofer PAZ, Schkopau, Germany M. Zscheyge, Fraunhofer IMWS, Schkopau, Germany

Abstract: Keywords: The research on light-weight composites especially thermoplastic-based materials is increasing the attention of lead engineers. It is because of low material cost, low production cycles, easy processability and recyclability. Thermoplastic sandwich structures, in combination with CFRTP face sheets and honeycomb core are the optimal material combinations in their segment. Thermoforming the semi-finished sandwich laminates into complex shapes increases their wide range of application. Using simulation tools this thermoforming process is optimized to check different forming conditions and process parameters, also different material combinations can be checked before going to trials. By modelling face sheet with fiber reinforcements and mapping the local fiber re-orientations, also modelling the honeycomb core structure and not homogenizing, the local deformations can be easily studied and used for structural analysis.

Thermoplastics, CFRTP, Honeycomb, Thermoforming Process, Modelling, Simulation, LS-DYNA

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Session "Automotive III: Welding"

Session Chairs: A. Blom-Schieber / I. Fernandez Villegas

1: Process Data Driven Advancement of Robot-based Continuous Ultrasonic Welding for the Dust-free Assembly of Future Fuselage Structures L. Larsen, DLR e. V., Augsburg, Germany F.J.C. Fischer, German Aerospace Center (DLR), Augsburg, Germany D. Görick, DLR e. V., Augsburg, Germany M. Engelschall, DLR e. V., Augsburg, Germany

Abstract: Keywords: The Center for Lightweight Production Technology in Augsburg (ZLP-AU) together with AIRBUS, Premium AEROTEC and Aernnova will deliver the 8m long upper half shell for the so-called multifunctional fuselage demonstrator (MFFD) within the greater European Clean Sky 2 large passenger aircraft (LPA) project. For this next generation fuselage demonstrator made of carbon fiber reinforced thermoplastics we have developed robot-based continuous ultrasonic welding (cUS) that will serve for stringer integration in final assembly of the single-aisle fuselage demonstrator. This study focuses the opportunities and challenges of the robot-based continuous ultrasonic welding process for a full scale fuselage demonstrator. To mature the welding process which can be very fragile on rough surfaces an in-line process monitoring system has been developed which predicts the achieved welding strength the process data in combination with artificial intelligence.

Continuous Ultrasonic Welding, Thermoplastic Composites, LM-PAEK, Artificial Intelligence, Automated Aerospace Assembly, Fuselage of Tomorrow

2: Recent Developments in Ultrasonic Welding of Epoxy- to Thermoplastic-based Composites E. Tsiangou, Delft University of Technology, Delft, Netherlands S. Teixeira de Freitas, Delft University of Technology, Delft, Netherlands I. Fernandez Villegas, Delft University of Technology, Delft, Netherlands

Abstract: Keywords: Thermoset composites can be welded through a neat, thermoplastic film (or coupling layer) that is co-cured on the surface of the laminate that needs to be welded. Ultrasonic welding possesses a great advantage over other welding and joining techniques in that it can offer exceptionally short heating times of less than 1 sec. These short heating times were found to significantly limit the risk of thermal degradation of the epoxy resin when welding carbon fiber (CF)/epoxy to CF/ polyetheretherketone adherends. The present work summarizes the results of a number of experimental studies that were performed in order to better

Ultrasonic Welding, Thermoplastic Composites, Thermoset Composites

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understand ultrasonic welding of such dissimilar composites. It is shown that ultrasonic welding of CF/epoxy- to thermoplastic-based composites is not only feasible but also offers certain flexibility with respect to changes in the coupling layer thickness, material of the ED and TPC adherend and process parameters.

3: Resistance Welding Simulation through Application and

Modification of Crystallisation Models A. Sänger*, Premium AEROTEC GmbH, Augsburg, Germany P. Sekol, Karlsruher Institut für Technologie, Karlsruhe, Germany M. Kupke, DLR e. V., Augsburg, Germany A. Baeten, Hochschule Augsburg, Augsburg, Germany T. Böhlke, Karlsruher Institut für Technologie, Karlsruhe, Germany P. Runeberg, Premium AEROTEC GmbH, Augsburg, Germany

Abstract: Keywords: A simulation is established for a resistance welding process of carbon fibre reinforced polyphenylene sulfide (CF/PPS). Crystallisation is seen as the key to understand the process and indicating later joint quality and strength. Therefore, a suitable crystallisation model is evaluated and found in the Modified Nakamura-Ziabicki. The simulation is modelled in ABAQUS with a HETVAL subroutine. Numerical adjustments and idealisations of boundary conditions are introduced to the existing material model. Simulation validation is carried out with experimental data and improvement measures are derived. Aspects on refinement of the simulation are presented.

Thermoplastics, Composites, Simulation, Crystallisation, Modelling, Nakamura-Ziabicki

29

4: Industrialisation Aspects for Ultrasonic Welding of Large Thermoplastic Aerospace Structures F. Köhler, CTC GmbH, Stade, Germany, and Delft University of Technology, Delft, Netherlands I. Fernandez Villegas, Delft University of Technology, Delft, Netherlands C. Dransfeld, Delft University of Technology, Delft, Netherlands A.S. Herrmann, CTC GmbH, Stade, Germany

Abstract: Keywords: Ultrasonic welding is a very promising technology to join fibre-reinforced thermoplastic composites. The process is characterised by low amplitude and high-frequency vibrations that are applied transversally to the welding surface allowing short heating times and fast processing. Although first steps towards application in the aerospace industry have already been taken, the process is still mostly applied in a laboratory environment. This paper focuses on the integration of different tooling concepts on actual aerospace components and the effect of tailored energy directors on the welding process. While fabrics show a rather homogeneous compaction in the melting stage or the welding process, unidirectional plies are prone to transverse squeeze flow, which can cause edge defects, decompaction and voids, which represents additional challenges in achieving robust processing conditions. Experimental and numerical quality assessment methods are applied to assess the influence of the different studied aspects towards an efficient industrialisation.

Thermoplastic Composites, Fusion Bonding, Continuous Ultrasonic Welding, Industrialisation, Energy Director

5: Focused Inductive Heat Generation in Weld Zones of Carbon Fibre Laminates by Magnetic Field Manipulation and Carbon Fibre Susceptors N. Menke, DLR e. V., Stade, Germany M. Dhondt, DLR e. V., Stade, Germany

Abstract: Keywords: Research is done into alternative composite joining techniques, as contemporary methods require extensive work. The application of induction welding, one of the three most researched composite welding techniques, results in less labour and defects compared to mechanical fastening. The downside of induction welding is that the heating rate is reciprocal to the distance between carbon fibres and inductor and thus the weld zone cannot be heated exclusively. As a yielding surface leads to an imperfect weld, the aim of this research was identifying induction heating techniques to selectively heat the weld zone, such as manipulation techniques of the magnetic field and application of CFRP susceptors. In addition, a verification for LSP is performed.

Induction, Welding, Selective, Magnetic Field Manipulation, Magnetic Field Orientation, Susceptor, Carbon Fiber Susceptor, CFRP, Thermoplastic

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Session "Emerging Technologies III: 3D Printing"

Session Chairs: P. Ermanni / M. Mayer

1: New Technique for Impregnating Rovings with High Viscous Melts M. Titze, DLR e. V., Braunschweig, Germany M. Rege, DLR e. V., Braunschweig, Germany J. Riemenschneider, DLR e. V., Braunschweig, Germany

Abstract: Keywords: The impregnation of rovings with high viscous melts is still a challenging task. A new technique developed by German Aerospace Center is shown, to achieve high impregnation quality within small installation space. This technology is based on the introduction of high frequency sound waves in a thermoplastic melt, which encloses a fiber roving. Possible application scenarios range from the production of continuous fiber-reinforced semi-finished products to the integration in a 3D-printing head.

Impregnation, Ultrasound, Additive Manufacturing

2: Characterization of Additively Manufactured Endless Fiber Reinforced Multi-material Composites M. Czasny, Technische Universität Berlin, Berlin, Germany S. Koerber, Technische Universität Berlin, Berlin, Germany O. Kaba, Technische Universität Berlin, Berlin, Germany N. Jain, Technische Universität Berlin, Berlin, Germany O. Goerke, Technische Universität Berlin, Berlin, Germany A. Gurlo, Technische Universität Berlin, Berlin, Germany

Abstract: Keywords: In this work we investigated the bonding and process combination of basic components with additively manufactured composites by our patend pending “Print Heat Infiltration (PHI)” technology and 3D printing with coextruded endless fiber reinforced filaments. The composite contain carbon fibers and PA6 matrix material. The basic components were made of PA12 by powder bed fusion and PA6 and PA12 by material extrusion. The combinations were analyzed by testing the sheer strength under different process parameters like speed, temperature and different pretreatments and further tests. These results and the combination of technologies enable lightweight products which cannot be fulfilled by unreinforced polymers in the field of medical applications like prosthetics and orthosis components sockets and engineering like lightweight design, functional prototypes.

Additive Manufacturing, 3D Printing, Material Extrusion, Thermoplastic Composite

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3: Seamless Solution for Industrial-grade Continuous Carbon Fibre 3D-printed Composites Y. Willemin, 9T Labs AG, Zürich, Switzerland M. Eichenhofer, 9T Labs AG, Zürich, Switzerland

Abstract: Keywords: Nowadays, the comparably high costs associated with carbon fiber composite parts to its aluminium or steel contenders, remain a constraining factor. A higher degree of freedom to optimize the part geometry and the fiber layup in combination with increased automation in manufacturing will reduce the current constraint. 3D printing, an additive manufacturing technology, is believed to deliver on those demands for manufacturing. 9T Labs’ radically all-in-one Red Series technology provides a fully integrated solution, starting from CAD design to final part. Therefore, it enables 3D printing of performance composites with high fiber volume content (>50%) materials, ensures part quality by introducing appropriate consolidations steps, and scales through parallelization of affordable printing units. 9T Labs’ all-in-one solution proved to be economically viable with up to twenty times lower development costs and up to ten times lower production costs through the seamless integration of software, 3d-print module, and consolidation module. Furthermore, this innovative approach allows up 50% more lightweight design for serial parts withstanding the required loadcases.

3D-Printing, Simulation, Consolidation, Composites, Automation

4: Development of a Test Bench for Fused Filament Fabrication A. Matschinski, Technische Universität München, Garching, Germany A. Juan Alburquerque, Technische Universität München, Garching, Germany B. Kriegl, Technische Universität München, Garching, Germany K. Kind, Technische Universität München, Garching, Germany K. Drechsler, Technische Universität München, Garching, Germany

Abstract: Keywords: The production of additively manufactured polymer components has significantly increased in several industries, especially in aeronautical and medical applications [1]. One of the commonly used processes is Fused Filament Fabrication (FFF). However, the certification of printed products is quite challenging due to instabilities in processing and comparatively poor properties of the produced parts. Quality of FFF parts, such as layer-layer adhesion or geometric fidelity, is mostly depending on the material flow. This flow is influenced by several parameters. One of the significant parameters is the fluid pressure inside the nozzle [4]. To demonstrate the viability of monitoring approaches and to establish a base to attain further TRLs we create a new

Additive Manufacturing, Fused Filament Fabrication, FFF, Test Bench, Online Process Monitoring, Fluid Pressure

32

test bench. The test bench is divided in several modules mirroring the steps of FFF, so sensors (e.g. pressure) can be placed along the process.

5: Large Scale 3D Printed Thermoplastic Composite Forms for Precast Concrete Structures S. Bhandari, University of Maine, Orono,USA R. Lopez-Anido, University of Maine, Orono, USA J. Anderson, University of Maine, Orono, USA

Abstract: Keywords: Recent advances in large-scale 3D printing and thermoplastic composite materials with bio-based fillers and reinforcements have great potential for expanding the possibilities of making forms for precast concrete structures. The 3D printing technology for making molds, forms and tooling for precast concrete is expected to reduce labor cost and minimize waste. 3D printed forms allow design optimization of precast concrete parts since the additive manufacturing cost is only function of thermoplastic material weight and is independent of part complexity. Additionally, 3D printed forms can become and asset, since thermoplastic composite materials can be reprocessed. A 16.5 m long 3D printed form for the precast concrete pier cap of highway bridge replacement project was selected for demonstration. The design and manufacturing of 3D printed forms for casting concrete encompass three steps, as follows: 1) Prediction and reduction of shrinkage effects; 2) Structural design for strength and stiffness requirements; and 3) Model slicing, part printing, and surface finishing. The type of surface finishing and the dimensional stability and durability of the thermoplastic material selected for concrete forms are examined. The lessons learned from the bridge project using large-scale 3D printing technology for formwork are summarized.

3D Printing, Additive Manufacturing, Form, Concrete, Bridge, Extrusion

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Poster

Poster 01: CAE Tools for Overmoulded Thermoplastic Composites – State-of-the-art and Future Developments

R. Enderle, Faserinstitut Bremen e. V., Bremen, Germany T. Schäfer, SimpaTec GmbH, Aachen, Germany A.S. Herrmann, Faserinstitut Bremen e. V., Bremen, Germany

Abstract: Keywords: In recent years, composite overmoulding technology was established in the automotive sector. In order to apply the technology also in the aerospace industry, several challenges are to be tackled. On the one hand, the processing technology must be adapted to high performance thermoplastics. On the other hand, a deeper understanding of the short- and long-term behaviour of such overmoulded structures is required. CAE tools such as numerical simulations of both, the manufacturing process and the structural mechanics, are possibly the best way to apply this understanding to new products. As in most other composite technologies, the manufacturing process determines the later mechanical properties of the structure. Consequently, the process-dependence of material and component properties is a core domain to be covered by CAE tools. Some of the phenomena are already modelled and available in commercial simulation software. Others still have to be further investigated and understood better before suitable models can be developed and integrated into commercial software. In our presentation we will give a comprehensive overview of the latest CAE tools that are available today to engineers who develop products made of overmoulded thermoplastic composites. Furthermore, we will talk about new developments which could become available in the near future. Among these, the prediction of interface quality and strength as well as residual stresses and warpage are highly demanded from the industry. Therefore, our latest research results on these topics will be presented.

Simulation, Material Modelling, Overmoulding, Interface Strength, High-performance Thermoplastics

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Poster 02: Out-of-autoclave Manufacturing of Thermoplastic Fuselage Skins with Integrated Stringers

G. Doll, DLR e. V., Stuttgart, Germany S. Bauer, DLR e. V., Stuttgart, Germany M. Horn, DLR e. V., Stuttgart, Germany

Abstract: Keywords: This work presents an investigation into the realisation of a thermoplastic fuselage skin with integrated stringers. In order to minimise costs for such a component, this study utilises an Out-of-Autoclave techniques and pre-finished secondary parts (stringers and fillers). The stringers will be integrated during the skin manufacturing without the need for additional joining. The process is optimized for a sufficient laminate quality and a sufficient quality of the weld line. The quality is assessed via Computational Tomography (CT), microscopy, and ultrasonic scanning.

Out of Autoclave, Stringer Integration

Poster 03: Evaluation on Rivet Fastening by Ultra-compact Servo Press Thermoforming

T. Eguchi, Dai-Ichi Dentsu Ltd., Kani-shi, Japan N. Ando, Kindai University, Higashiosaka-shi, Japan T. Hasegawa, Kindai University, Higashiosaka-shi, Japan D. Tanabe, Kobe City College of Technology, Kobe-shi, Japan K. Nishiyabu, Kindai University, Higashiosaka-shi, Japan

Abstract: Keywords: This study aims to evaluate fastening capability of unidirectional carbon fiber reinforced thermoplastics(UD-CFRTP) rivet. The UD-CFRTP rivets is fastening by rapid heating of a CFRTP round rod by a near-infrared heater and press forming by a servo press capable of controlling loads displacement. In this study, the effects of heating method, forming load and heating temperature on fastening behavior were investigated. The contents for evaluation are heating distribution of UD-CFRTP rivet, pressure loading behavior, cross-sectional observation after joining, tensile shear strength test and pull-through strength test. The joining strength of test specimens joined by the A5052 rivet and epoxy adhesive bonding were also investigated. The experimental results showed that the UD-CFRTP rivet had the tensile shear strength of 200 MPa and the pull-through strength of 1658N, which was much higher than the other joints.

CFRTP, Rivet, Fastening, CF/PA6, CF/PEEK, Joining Strength

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Poster 04: The Investigation of Advanced Thermoplastic Composite Materials in Aerospace Applications

Z. Yavuz, Turkish Aerospace Inc., Ankara, Turkey M. Bakir, Turkish Aerospace Inc., Ankara, Turkey

Abstract: Keywords: Composite materials which are currently being used in aerospace applications are mainly based on thermosets, particularly epoxy resins in pre-impregnated composite fibers. Although their mechanical strength, high levels of dimensional stability and cost-effective manufacturing thermoset composites have considerable drawbacks. They cannot be recycled, cannot be remolded or reshaped, moreover they are difficult to surface finish. On the other hand, instead of using thermoset based composite matrices proceeding with thermoplastics is more advantageous since fiber reinforced thermoplastic prepregs provide high-impact resistance, remolding/reshaping capabilities, chemical resistance and long lifetime. In our research, we develop thermally and chemically stable, also mechanically superior thermoplastic composites via novel fiber sizing technique.

Thermoplastics, Composites, Fibers, Sizing

Poster 05: Investigation of Material Extrusion based Print Heads for Thermoplastic Composites by Internal Pressure Analysis

O. Kaba, Technische Universität Berlin, Berlin, Germany M. Czasny, Technische Universität Berlin, Berlin, Germany S. Koerber, Technische Universität Berlin, Berlin, Germany O. Goerke, Technische Universität Berlin, Berlin, Germany A. Gurlo, Technische Universität Berlin, Berlin, Germany

Abstract: Keywords: With the maturation of Additive Manufacturing technologies, fiber and particle reinforced thermoplastics are promising composites, which close the gap between overall higher material strength and processability in the material extrusion technology. To investigate the relations between print head geometry and flow behavior of printed material, the internal pressure within the printhead will be analyzed. For this purpose a test setup was built to characterize and evaluate different print heads when printing with fiber and particle reinforced thermoplastics and give scientific insights about their relations.

Additive Manufacturing, 3D Printing, Material Extrusion, Thermoplastic Composite, Print Head, Testing

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Poster 06: eVTOL Fan Casing with Integral Stiffeners and Attachment Points

C. Garthaus, herone GmbH, Dresden, Germany F. Assmann, herone GmbH, Dresden, Germany D. Barfuss, herone GmbH, Dresden, Germany

Abstract: Keywords: High performance and ambitious cost targets characterize the demand for parts of the new arising market of electrical vertical take-off and landing aircraft vehicles (eVTOL). Enhanced functionality through more integral structures in combination with fully automated, resource efficient and environmentally friendly production technologies are a promising solution approach to satisfy this demand. High performance thermoplastic composites like CF-PAEK offer the mechanical and processing properties to achieve more integral designs while enabling high production rates. In this article, a one-step production approach with 20 min cycle time for an integral CF/GF-PAEK fan casing with integrated stiffeners and attachment points is presented.

All Thermoplastic Composite Design, Tapes, Tape-preforms, Profiles, Function Integration

Poster 07: Welding of UD Carbon LM-PAEK and PEKK Tapes M. Labordus, KVE Composites Group, The Hague, Netherlands T. Jansen, KVE Composites Group, The Hague, Netherlands T. Salat, RESCOLL Société de Recherche, Pessac, France

Abstract: Keywords: The CleanSky project MECATESTERS (acronym for Micro mEchanical Characterization of A ThErmoplastic Co-conSolidated/welded joinT for usE in aiRcraft fuSelages) project, with GKN Fokker as topic mananger, represents a key step in the progression of welding technologies to widespread use in the aerospace sector. Within MECATESTERS, KVE Composites Group and Rescoll cooperate to create a greater level of understanding of the micromechanical behaviour of the welded interfaces for UD tape-based laminates, an understanding which is currently mainly limited to carbon fabric-based laminates. Issues such as aging, healing, processing parameters, and durability are investigated in greater detail in order to develop a coherent approach. Laminates from three types of UD tape are produced (a 134 and 194 gsm LM-PAEK tape from Toray and a 145 gsm PEKK tape from Solvay Cytec), in 2.2 and 2.8mm thickness. Two welding processes are investigated: induction welding and conduction welding. The influence of welding pressure, welding temperature and cool-down rate is quantified. This paper describes the test matrix, the manufacturing of the thermoplastic laminates, the welding of the coupons and gives the first results from non-destructive testing and mechanical testing.

Induction Welding, Conduction Welding, LM-PAEK, Thermoplastic Tapes

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Poster 08: Experimental and Numerical Research of the MM Welding® Joining Technology for Sandwich Panels

I. Zhilyaev, Fachhochschule Nordwestschweiz, Windisch, Switzerland C. Brauner, Fachhochschule Nordwestschweiz, Windisch, Switzerland L.. Zweifel, Fachhochschule Nordwestschweiz, Windisch, Switzerland M. Rhême, MM MultiMaterial-Welding GmbH, Biel, Switzerland G. Eckhard, MM MultiMaterial-Welding GmbH, Biel, Switzerland V. Bersier, MM MultiMaterial-Welding GmbH, Biel, Switzerland R. Ricardo, KVT-Fastening, Dietikon, Switzerland

Abstract: Keywords: Sandwich-structured composite materials provide clear advantages on weight savings and mechanical performance in the aerospace and automotive industry. Creating connection points for sandwich structured composites without losing technical performance is one of the key technologies, leading to optimal light-weight structures. MultiMaterial-Welding AG invented and patented the LiteWWeight® technology, that allows more effective connections on sandwich panels than traditional fastening methods. Ultrasonic equipment is used to insert a thermoplastic fastener into the substrate material and partially melt it into the porous internal structure, creating a highly interlocked mechanical bond. This study deals with the analysis and simulation of the pin and substrate material interaction during the connection process. For this purpose, material characterization was conducted, and an online process monitoring system was developed to capture data from multiple force and displacement sensors. Experimental test series were performed to obtain time-dependent process data, including high-speed video of the process coupled with point-tracking algorithms and CT-scanning of the sandwich structure. Based on the collected data, thermo-mechanical model was developed in ABAQUS, and a parametric study coupled with machine learning methods was carried out to identify unknown model parameters. FEM describes the respective pin behavior, as it depends on the geometry of the pin, the material properties, the structure of the substrate material and the process setup. Developed models were coupled with machine learning and optimization methods (MM-Welding SmartSolutions) and then integrated into a Smart Robotic MM-Welding® automation concept, where ultrasonic actuator is attached to a 6-axis robot arm, which enables joining in diverse positions.

Sandwich-structured Composite, Thermoplastic Fastener, Lightweight Structures, FEM Thermo-mechanical Simulation

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Poster 09: Polyamide 6 Carbon Fiber Composites obtained by T-RTM: Thermal, Chemical and Mechanical Characterization

F. P. Martins*, University of Aveiro, Oliveira de Azeméis, Portugal J. M. Oliveira, University of Aveiro, Oliveira de Azeméis, Portugal

Abstract: Keywords: Thermoplastic-Resin Transfer Moulding (T-RTM) is a technology under development that allows the production of thermoplastic-based composites via anionic opening of the ε-caprolactam ring. This method requires low processing temperatures (≈140-180°C) and a fast polymerization time (≈5-30 min). Polyamide 6 (PA6) and PA6 carbon fibre samples are produced using a homemade T-RTM equipment. The thermal, physical-chemical and mechanical behaviour of the PA6 and PA6 reinforced samples are close to commercial PA6 and PA6 carbon fibre samples found in the literature, respectively.

Polyamide 6, Thermoplastic Matrix Composite, T-RTM, Lightweight, Automotive Structural Components

Poster 10: Towards an Increased Reliability of Resistance Welded Joints for Aircraft Assembly

M. Endrass, DLR e. V., Augsburg, Germany S. Jarka, DLR, Augsburg, Germany S. Bauer, DLR e. V., Augsburg, Germany F.J.C. Fischer, DLR e. V., Augsburg, Germany L. Larsen, DLR e. V., Augsburg, Germany M. Kupke, DLR e. V., Augsburg, Germany

Abstract: Keywords: This study focuses the opportunities and challenges of the static resistance welding (RW) process applied to a full scale fuselage demonstrator. An adapted RW setup and process is described producing high quality welds over the whole welding surface with a defined weld seam. The effects of scaling and the challenges that arise during the welding of the demonstrator are described. Approaches to solutions are presented to meet the required reliability of resistance welded joints in application.

Resistance Welding, Thermoplastic Composites, LM-PAEK, Upscaling, Assembly Technologies, Process Control and Monitoring

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Poster 11: ConThP: Consolidation of Thermoplastic Hybrid Yarn Materials

R. Vocke*, Faserinstitut Bremen e. V., Bremen, Germany V. Werlen*, Fachhochschule Nordwestschweiz, Windisch, Switzerland, and Ecole Polytechnique Fédérale de Lausanne, Lausanne, Switzerland C. Rytka, Fachhochschule Nordwestschweiz, Windisch, Switzerland P. Schwanemann, Faserinstitut Bremen e. V., Bremen, Germany V. Michaud, Ecole Polytechnique Fédérale de Lausanne, Lausanne, Switzerland C. Dransfeld, Delft University of Technology, Delft, Netherlands C. Brauner, Fachhochschule Nordwestschweiz, Windisch, Switzerland A.S. Herrmann, Faserinstitut Bremen e. V., Bremen, Germany

Abstract: Keywords: Hybrid yarn materials are rarely used since the simulation of complex shapes is not possible with state-of-the-art models. Therefore, a 3D consolidation approach is developed and implemented into finite element analysis. Impregnation is investigated based on a model textile topology consisting of quasi-unidirectional weave layers and low melt PAEK, PEKK or PEI thermoplastic fibre layers. The constituents are characterized including rheological and thermal analyses as well as single fibre pull-out tests. We propose an impregnation model developed for this topology and its associated process and present comparison to experimental data. The results show that high fibre volume fractions are desirable and achievable with the right processing conditions.

Hybrid Yarn Materials, Consolidation, Fiber-reinforced Thermoplastics, PAEK, PEKK, PEI, Impregnation Model

Poster 12: Density Influence on the Formation of Skin Layers in Integral Sandwich Structures based on Open Pore PESU Foams

M. Salmins*, Institut für Verbundwerkstoffe GmbH, Kaiserslautern, Germany P. Mitschang, Institut für Verbundwerkstoffe GmbH, Kaiserslautern, Germany

Abstract: Keywords: PESU-based polymer foams have a high potential for the application in passenger transport aircraft interior components due to their inherent flame retardant properties and low densities. This study focusses on the impact of the properties initial density and thickness of two different semi-finished products, and the parameters temperature and pressure on the formation of skin layers in the hot press process to process creates integral sandwich structures with superior mechanical properties.

Integral Sandwich, Hot Press Process, Polymer Foam,

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Poster 13: Development of High Cycle Rivet Fastening Process by Ultra-compact Servo Press Machine using Unidirectional CFRTP Rivet

T. Eguchi, Dai-Ichi Dentsu Ltd., Kani-shi, Japan D. Tanabe, Kobe City College of Technology, Kobe-shi, Japan K. Nishiyabu, Kindai University, Higashiosaka-shi, Japan

Abstract: Keywords: This study aims to evaluate the rivet fastening process of unidirectional carbon fiber reinforced thermoplastics (UD-CFRTP) using an ultra-compact servo press machine with near-infrared heating developed by the authors. In this compact and lightweight portable machine, the precise control of UD-CFRTP rivet fastening was realized. This lightweight port

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