Lab-based in-situ micro-CT observation of gaps in prepreg laminates during consolidation and cure

James Kratz; Pedro Galvez-Hernandez; Laura Rhian Pickard; Jonathan Belnoue; Kevin Potter

doi:10.1016/j.compositesa.2020.106180

Lab-based in-situ micro-CT observation of gaps in prepreg laminates during consolidation and cure

James Kratz^*, Pedro Galvez-Hernandez, Laura Rhian Pickard, Jonathan Belnoue, Kevin Potter

^*Corresponding author for this work

Research output: Contribution to journal › Article (Academic Journal) › peer-review

9 Citations (Scopus)

58 Downloads (Pure)

Abstract

An experimental technique was developed to obtain 3D microstructural information on two typical lay-up features that often appear in automated fibre placement (AFP) or automated tape laying (ATL). Parallel-ply gaps between adjacent courses and ply-drop gaps needed to change the thickness of composite laminates were studied. Using a lab-based CT scanner, the different squeezing and bleeding mechanisms were observed while the manufacturing process was occurring. The initially large gaps were closed by fibre and/or resin flow, with the parallel-ply gap consolidating faster and reaching a lower porosity level than the ply-drop gap. However, after reaching a minimum porosity, previously consolidated voids reappeared and remained locked into the final microstructure. The in-situ CT data was helpful to identify opportunities for future process model developments. Overall, lab-based in-situ micro-CT was proven to be an effective and accessible technique to study how composite features evolve through the manufacturing process.

Original language	English
Article number	106180
Number of pages	13
Journal	Composites Part A: Applied Science and Manufacturing
Volume	140
Early online date	28 Oct 2020
DOIs	https://doi.org/10.1016/j.compositesa.2020.106180
Publication status	Published - 1 Jan 2021

Bibliographical note

Funding Information:
The authors would like to acknowledge the Engineering and Physical Sciences Research Council ( EPSRC ) for their support of this research through Investigation of Fine-Scale Flows in Composites Processing [ EP/S016996/1 ]. PhD studentship for P. Galvez-Hernandez was supported through the Rolls-Royce Composites University Technology Centre at the University of Bristol. EngD studentship for L.R. Pickard was supported through the Centre for Doctoral Training in Composites Manufacture [EP/K50323X/1] and the National Composites Centre. The authors would like to thank Katie Smith for supporting the experimental campaign.

Funding Information:
The authors would like to acknowledge the Engineering and Physical Sciences Research Council (EPSRC) for their support of this research through Investigation of Fine-Scale Flows in Composites Processing [EP/S016996/1]. PhD studentship for P. Galvez-Hernandez was supported through the Rolls-Royce Composites University Technology Centre at the University of Bristol. EngD studentship for L.R. Pickard was supported through the Centre for Doctoral Training in Composites Manufacture [EP/K50323X/1] and the National Composites Centre. The authors would like to thank Katie Smith for supporting the experimental campaign.

Publisher Copyright:
© 2020 Elsevier Ltd

Keywords

E. Prepreg processing
D. CT analysis
C. Process simulation
E. Automated fibre placement (AFP)

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10.1016/j.compositesa.2020.106180

Full-text PDF (author’s accepted manuscript)
This is the author accepted manuscript (AAM). The final published version (version of record) is available online via Elsevier at https://doi.org/10.1016/j.compositesa.2020.106180. Please refer to any applicable terms of use of the publisher.
Accepted author manuscript, 2.05 MBLicence: CC BY-NC-ND

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Investigation of fine-scale flows in composites processing
Rendall, T. C. S.
1/04/19 → 31/03/23
Project: Research

Towards Efficient Composites Manufacture Through In-Process Monitoring and Knowledge Management
Author: Pickard, L. R., 25 Jun 2019
Supervisor: Partridge, I. (Supervisor), Potter, K. (Supervisor), Kells, D. (External person) (Supervisor) & Shakspeare, P. (External person) (Supervisor)
Student thesis: Doctoral Thesis › Engineering Doctorate (EngD)

File

In-situ CT gaps
Allegri, G. (Creator), Hallett, S. R. (Creator), Partridge, I. (Creator), Clegg, H. (Creator), Kratz, J. (Contributor), Hartley, J. (Creator), Zhang, B. (Creator), Melro, A. R. (Creator) & Galvez Hernandez, P. (Creator), University of Bristol, 20 Oct 2020
DOI: 10.5523/bris.cpunp7ml1s5t2owhutk6hj7gd, http://data.bris.ac.uk/data/dataset/cpunp7ml1s5t2owhutk6hj7gd
Dataset

Cite this

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abstract = "An experimental technique was developed to obtain 3D microstructural information on two typical lay-up features that often appear in automated fibre placement (AFP) or automated tape laying (ATL). Parallel-ply gaps between adjacent courses and ply-drop gaps needed to change the thickness of composite laminates were studied. Using a lab-based CT scanner, the different squeezing and bleeding mechanisms were observed while the manufacturing process was occurring. The initially large gaps were closed by fibre and/or resin flow, with the parallel-ply gap consolidating faster and reaching a lower porosity level than the ply-drop gap. However, after reaching a minimum porosity, previously consolidated voids reappeared and remained locked into the final microstructure. The in-situ CT data was helpful to identify opportunities for future process model developments. Overall, lab-based in-situ micro-CT was proven to be an effective and accessible technique to study how composite features evolve through the manufacturing process.",

keywords = "E. Prepreg processing, D. CT analysis, C. Process simulation, E. Automated fibre placement (AFP)",

author = "James Kratz and Pedro Galvez-Hernandez and Pickard, {Laura Rhian} and Jonathan Belnoue and Kevin Potter",

note = "Funding Information: The authors would like to acknowledge the Engineering and Physical Sciences Research Council ( EPSRC ) for their support of this research through Investigation of Fine-Scale Flows in Composites Processing [ EP/S016996/1 ]. PhD studentship for P. Galvez-Hernandez was supported through the Rolls-Royce Composites University Technology Centre at the University of Bristol. EngD studentship for L.R. Pickard was supported through the Centre for Doctoral Training in Composites Manufacture [EP/K50323X/1] and the National Composites Centre. The authors would like to thank Katie Smith for supporting the experimental campaign. Funding Information: The authors would like to acknowledge the Engineering and Physical Sciences Research Council (EPSRC) for their support of this research through Investigation of Fine-Scale Flows in Composites Processing [EP/S016996/1]. PhD studentship for P. Galvez-Hernandez was supported through the Rolls-Royce Composites University Technology Centre at the University of Bristol. EngD studentship for L.R. Pickard was supported through the Centre for Doctoral Training in Composites Manufacture [EP/K50323X/1] and the National Composites Centre. The authors would like to thank Katie Smith for supporting the experimental campaign. Publisher Copyright: {\textcopyright} 2020 Elsevier Ltd",

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AU - Kratz, James

AU - Galvez-Hernandez, Pedro

AU - Pickard, Laura Rhian

AU - Belnoue, Jonathan

AU - Potter, Kevin

N1 - Funding Information: The authors would like to acknowledge the Engineering and Physical Sciences Research Council ( EPSRC ) for their support of this research through Investigation of Fine-Scale Flows in Composites Processing [ EP/S016996/1 ]. PhD studentship for P. Galvez-Hernandez was supported through the Rolls-Royce Composites University Technology Centre at the University of Bristol. EngD studentship for L.R. Pickard was supported through the Centre for Doctoral Training in Composites Manufacture [EP/K50323X/1] and the National Composites Centre. The authors would like to thank Katie Smith for supporting the experimental campaign. Funding Information: The authors would like to acknowledge the Engineering and Physical Sciences Research Council (EPSRC) for their support of this research through Investigation of Fine-Scale Flows in Composites Processing [EP/S016996/1]. PhD studentship for P. Galvez-Hernandez was supported through the Rolls-Royce Composites University Technology Centre at the University of Bristol. EngD studentship for L.R. Pickard was supported through the Centre for Doctoral Training in Composites Manufacture [EP/K50323X/1] and the National Composites Centre. The authors would like to thank Katie Smith for supporting the experimental campaign. Publisher Copyright: © 2020 Elsevier Ltd

PY - 2021/1/1

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N2 - An experimental technique was developed to obtain 3D microstructural information on two typical lay-up features that often appear in automated fibre placement (AFP) or automated tape laying (ATL). Parallel-ply gaps between adjacent courses and ply-drop gaps needed to change the thickness of composite laminates were studied. Using a lab-based CT scanner, the different squeezing and bleeding mechanisms were observed while the manufacturing process was occurring. The initially large gaps were closed by fibre and/or resin flow, with the parallel-ply gap consolidating faster and reaching a lower porosity level than the ply-drop gap. However, after reaching a minimum porosity, previously consolidated voids reappeared and remained locked into the final microstructure. The in-situ CT data was helpful to identify opportunities for future process model developments. Overall, lab-based in-situ micro-CT was proven to be an effective and accessible technique to study how composite features evolve through the manufacturing process.

AB - An experimental technique was developed to obtain 3D microstructural information on two typical lay-up features that often appear in automated fibre placement (AFP) or automated tape laying (ATL). Parallel-ply gaps between adjacent courses and ply-drop gaps needed to change the thickness of composite laminates were studied. Using a lab-based CT scanner, the different squeezing and bleeding mechanisms were observed while the manufacturing process was occurring. The initially large gaps were closed by fibre and/or resin flow, with the parallel-ply gap consolidating faster and reaching a lower porosity level than the ply-drop gap. However, after reaching a minimum porosity, previously consolidated voids reappeared and remained locked into the final microstructure. The in-situ CT data was helpful to identify opportunities for future process model developments. Overall, lab-based in-situ micro-CT was proven to be an effective and accessible technique to study how composite features evolve through the manufacturing process.

KW - E. Prepreg processing

KW - D. CT analysis

KW - C. Process simulation

KW - E. Automated fibre placement (AFP)

U2 - 10.1016/j.compositesa.2020.106180

DO - 10.1016/j.compositesa.2020.106180

M3 - Article (Academic Journal)

SN - 1359-835X

VL - 140

JO - Composites Part A: Applied Science and Manufacturing

JF - Composites Part A: Applied Science and Manufacturing

M1 - 106180

ER -

Lab-based in-situ micro-CT observation of gaps in prepreg laminates during consolidation and cure

Abstract

Bibliographical note

Keywords

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Projects

Investigation of fine-scale flows in composites processing

Student theses

Towards Efficient Composites Manufacture Through In-Process Monitoring and Knowledge Management

Datasets

In-situ CT gaps

Cite this