An investigation into engineered thermoplastic polymer composite filament for through thickness reinforcement of laminated carbon fibre composites.
Lead Research Organisation:
University of Ulster
Department Name: School of Engineering
Abstract
Laminated composites from dry carbon fibre preforms are increasingly being used to produce primary structures in several industries. However, the poor performance in the out-of-plane (through the thickness) direction, and delamination has been a cause of concern, requiring the careful analysis of load paths to limit out-of plane stress. Furthermore, this has a limiting effect on the design freedom for composite components and could challenge the use of composites for future aerodynamic or structural concepts. Several 'first-generation' methods have been proposed to improve out-of-plane performance including z-pinning, selective interlayers and hybrids, protective layers or resin toughening; one method that is becoming increasingly successful is to reinforce composites with a fibre that connects the layers together running from the upper to lower surface of the laminate. This method shows potential but has been limited by the lack of suitable materials available for through-thickness reinforcement where we have hitherto been limited to carbon fibre, glass, basalt, Aramid or other polymeric fibres. Also, there is a limited understanding of the mechanisms involved in out-of-plane rate-dependent response of composite materials. This proposal aims to develop a new understanding of through-thickness reinforcement and to research a method to produce composites with a through-thickness response which is designer defined. This will be done by placing a 'second-generation' manufactured yarn with optimised properties in the through-thickness direction, thereby enabling the design of optimum Ez (laminate through-thickness Young's modulus) for a given loading scenario. The new yarn will be made by compounding extrusion of a thermoplastic monofilament reinforced with carbon fibres of specified length, optimising material and process parameters, and using these yarns as through-thickness reinforcement in carbon fibre/epoxy laminates. The performance will be characterised and a predictive analytical elastic stiffness model will be developed. Also, the visco-elastic properties of the new through thickness yarn will be related to the transverse impact performance of the laminated composite. These subjects have not been previously researched and if successful, the results could be transformative and generate global impact for UK composites research and industry. In the future the research will benefit aerospace companies; with the proposed enhanced out-of-plane performance they could potentially design a pressurised blended wing, composite lug arrangement, stringer to skin interface and run-out, buckling critical locations, high impact locations, etc.
Planned Impact
This project will potentially benefit many users of composite materials as structural load carrying elements, or as blast-protection products. In the future, the research will directly benefit UK aerospace companies; with the proposed enhanced out-of-plane performance they could potentially design a composite lug arrangement, stringer to skin interface and run-out, buckling critical locations, high impact locations, etc. The enhanced properties mean that the knock-down factors applied to the design such as barley viable impact damage (BVID) will be reduced. Also, initial research has shown that notch sensitivity and stress concentration caused by open-holes is reduced. Currently, the overall structural weight of an aircraft is increased by over 10% to allow for these factors. By developing new materials and understanding, the designers will be able to reduce this conservatism, reduce weight of the airframe and therefore, fuel burn. This will have a greater environmental impact with reduction in greenhouse gas. Furthermore, new ultra-efficient aircraft designs such as the Boeing X-48C Blended Wing Body Research Aircraft (Environmentally Responsible Aviation project) might not be feasible with existing composite laminates due to the large out-of-plane stresses the composite pressurised blended wing would experience. This research therefore, is vital for the UK at this time. These new aircraft will reduce community noise, fuel burn and nitrogen oxides (NOx) emissions. These aircraft might enter service by 2025.
The UK is currently well positioned to benefit economically from these new technologies through the supply chain. A UKTI (UK Trade & Investment) and BIS market report completed in April 2010 and published in 2011 entitled 'UK Composites Supply Chain Scoping Study - Key Findings' estimated that there were 1,500 companies in the UK composites sector producing added value of around £1.1 billion. The UK aerospace industry represents 17% of global market and is the 2nd largest globally. The first generation laminated composite primary structures are now flying, so there is an urgent need to develop new performance and a move away from the current 2D design strategies. This could be realised in the medium term during a re-engineering of the existing aircraft in search of fuel efficiency (5 years) or on the next generation aircraft (10 years). This project however will aid development of composites structure capability in sectors other than aerospace. With the proposed new through thickness yarn and preforming methods, the automotive industry could increase deposition rates of composite materials, therefore reducing manufacturing costs. Through the proposed Pathways to impact, the information generated in this project will also be disseminated to the marine industry through an existing KTP, the renewables sector through a Marie Curie programme, and could influence existing DSTL research undertaken at University of Ulster.
The UK is currently well positioned to benefit economically from these new technologies through the supply chain. A UKTI (UK Trade & Investment) and BIS market report completed in April 2010 and published in 2011 entitled 'UK Composites Supply Chain Scoping Study - Key Findings' estimated that there were 1,500 companies in the UK composites sector producing added value of around £1.1 billion. The UK aerospace industry represents 17% of global market and is the 2nd largest globally. The first generation laminated composite primary structures are now flying, so there is an urgent need to develop new performance and a move away from the current 2D design strategies. This could be realised in the medium term during a re-engineering of the existing aircraft in search of fuel efficiency (5 years) or on the next generation aircraft (10 years). This project however will aid development of composites structure capability in sectors other than aerospace. With the proposed new through thickness yarn and preforming methods, the automotive industry could increase deposition rates of composite materials, therefore reducing manufacturing costs. Through the proposed Pathways to impact, the information generated in this project will also be disseminated to the marine industry through an existing KTP, the renewables sector through a Marie Curie programme, and could influence existing DSTL research undertaken at University of Ulster.
Organisations
- University of Ulster (Lead Research Organisation)
- CIMComp (Collaboration)
- University of Stuttgart (Collaboration)
- BOMBARDIER INC. (Collaboration)
- Athlone Institute of Technology (Collaboration)
- Bombardier Aerospace (Project Partner)
- Evonik (Switzerland) (Project Partner)
- Axis Composites Limited (Project Partner)
- EireComposites Teo (Project Partner)
- University College Dublin (Project Partner)
People |
ORCID iD |
Edward Archer (Principal Investigator) |
Publications
Ralph C
(2021)
Influence of binder float length on the out-of-plane and axial impact performance of 3D woven composites
in Composites Part A: Applied Science and Manufacturing
McGarrigle C
(2017)
Extruded Monofilament and Multifilament Thermoplastic Stitching Yarns
in Fibers
Clarke J
(2022)
A Cost Model for 3D Woven Preforms
in Journal of Composites Science
Noble T
(2021)
Powder Epoxy for One-Shot Cure, Out-of-Autoclave Applications: Lap Shear Strength and Z-Pinning Study
in Journal of Composites Science
McGarrigle C
(2019)
Extruded high-temperature thermoplastic tufting yarns for enhanced mechanical properties of composites
in Journal of Reinforced Plastics and Composites
McGarrigle C
(2022)
Influence of extrusion parameters on filled polyphenylsulfone tufting yarns on open-hole tensile strength
in Journal of Reinforced Plastics and Composites
Dooher T
(2017)
Novel thermoplastic yarn for the through-thickness reinforcement of fibre-reinforced polymer composites
in Journal of Thermoplastic Composite Materials
DALTON B
(2015)
ADVANCED MATERIALS FOR DEMANDING APPLICATIONS
Description | To date we have produced and characterised a range of (including high temperature) polymer yarns which have been used to stitch carbon fibre laminates together to provide through thickness reinforcement and improve delamination resistance. In addition we have also researched and produced multi-filament yarns. The yarns have been sent to Institut für Flugzeugbau for tufting trials and will then be tested at Ulster University and in collaboration with other research centres. |
Exploitation Route | We are currently working on 2 comference papers and will develop 2 Journal papers. The developed yarns will be supplied to other research programmes such as the ICONIC EU H2020 programme. ICONIC is a multinational Marie Sklodowska-Curie Innovative Training Network (ITN) funded by the European Union's Horizon 2020 programme. |
Sectors | Aerospace Defence and Marine Leisure Activities including Sports Recreation and Tourism Transport |
URL | https://www.researchgate.net/project/Novel-stitching-yarn-to-improve-the-interlaminar-mechanical-properties-of-fibre-reinforced-polymer-composites |
Description | We have used the findings to build a machine in collaboration with a local SME, this will increase the TRL of the technology. |
First Year Of Impact | 2021 |
Sector | Aerospace, Defence and Marine,Energy,Transport |
Impact Types | Economic |
Description | DEL PhD |
Amount | £30,000 (GBP) |
Organisation | Government of Northern Ireland |
Department | Department for Employment and Learning Northern Ireland (DELNI) |
Sector | Public |
Country | United Kingdom |
Start | 09/2016 |
End | 10/2019 |
Description | EU Marie Curie |
Amount | € 2,500,000 (EUR) |
Funding ID | FP7 - 612531 |
Organisation | Marie Sklodowska-Curie Actions |
Sector | Charity/Non Profit |
Country | Global |
Start | 02/2014 |
End | 01/2018 |
Description | Innovate UK Strength in Places Fund |
Amount | £30,000,000 (GBP) |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 08/2020 |
End | 01/2024 |
Description | NIACE Complex Preforming |
Amount | £100,000 (GBP) |
Organisation | Invest Northern Ireland |
Sector | Public |
Country | United Kingdom |
Start | 09/2015 |
End | 04/2017 |
Description | RESEARCH FELLOWSHIP SCHEME |
Amount | £59,000 (GBP) |
Organisation | Ulster University |
Sector | Academic/University |
Country | United Kingdom |
Start | 01/2015 |
End | 12/2017 |
Description | The Future Composites Manufacturing Hub |
Amount | £49,942 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 03/2019 |
End | 11/2019 |
Description | Athlone Institute of Technology |
Organisation | Athlone Institute of Technology |
Country | Ireland |
Sector | Academic/University |
PI Contribution | Ulster University visited Athlone Institute of Technology and worked with them on extrusion trials. The yarns were supplied to Ulster for stitching and weaving trials. |
Collaborator Contribution | Athlone Institute of Technology let us use their Eurotech single screw extruder with fibre spinning set-up. |
Impact | A paper will be published soon. |
Start Year | 2016 |
Description | Bombardier Aerospace |
Organisation | Bombardier Inc. |
Country | Canada |
Sector | Private |
PI Contribution | We supplied tufted preforms using a range of our materials developed during the process. We will also test these plaques and share the data with Bombardier. |
Collaborator Contribution | Bombardier have used their RTI process to infuse further test plaques for this project. |
Impact | None to date but will be presented in the next year. |
Start Year | 2017 |
Description | EPSRC Future Composites Manufacturing Research Hub |
Organisation | CIMComp |
Sector | Academic/University |
PI Contribution | Successful follow-on EPSRC Future Composites Manufacturing Research Hub funding granted. Ulster was invited to join the prestigious Hub as the only Irish University member. ulster university has provided a funded PhD to work on the project. |
Collaborator Contribution | Funding was provided to further research the technology and develop an improved methodology. |
Impact | A presentation was given at Advanced Engineering 2019, 30 - 31 Oct 2019 . |
Start Year | 2019 |
Description | Institut für Flugzeugbau - Faserverbundtechnologie |
Organisation | University of Stuttgart |
Department | Institute of Aircraft Design |
Country | Germany |
Sector | Academic/University |
PI Contribution | Ulster University manufactured a range of stitching yarns and sent them to Institut für Flugzeugbau . At the Institut für Flugzeugbau the yarns were used to tuft carbon fibre preforms which will be tested soon. |
Collaborator Contribution | Ulster provided the polymer yarns and Carbon Fibre. Institut für Flugzeugbau provided in-kind tufting of the preforms. |
Impact | 2 members from Ulster visited Institut für Flugzeugbau and further collaboration is expected. |
Start Year | 2017 |
Description | The results were presented to the wider industrial sector at Advanced Engineering 30 - 31 Oct 2019. |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Industry/Business |
Results and Impact | The EPSRC Future Composites Manufacturing Research Hub (The Hub) were exhibiting and speaking at this year's Advanced Engineering Show, taking place on 30th- 31st October at the NEC, Birmingham, UK. Visitors to the show were able to visit The Hub at Stand O54 where they will be displaying the latest information from its projects. Visitors were also invited to attend Open Forum on 13:00 on Day 1 where members of the team will be introducing The Hub and discussing its outputs and future direction: Archer presented on 'Controlled Micro Integration of Through Thickness Polymeric Yarns'. Industrial Engineers attended the presentation which sparked discussion afterwards. |
Year(s) Of Engagement Activity | 2019 |
URL | https://cimcomp.ac.uk/hub-news/advanced-engineering-show-2019/ |