Abstract
In this thesis, the development of a new manufacturing technique is presented, which aims to reimagine advanced composites manufacture for the automotive industry. The target is to produce complex geometry: low cost (less than £5/kg): high volume (~250k per annum) parts as would be seen for body panels. To achieve this, the present accepted composites manufacturing process of dry fibre plies infused with a low viscosity resin is replaced, owing to the fact it is unable to meet the demands of the automotive sector. Fundamental to this is the need to preform the plies to a stiff handleable laminate, which contributes over 50% of the total time to manufacture.The fundamentally different approach proposed within these pages still utilises a dry fibre composite preform, but it is now held in shape by an external thermoplastic shell, removing the need for binder within the preform. The shell provides geometric stability for the preform and protects it during more typical automated/robotic transit, removing both the costly time impact of binder activation and the quality impact this has on the final part. The shell-protected preform is placed inside a heated press system, enabling the thermoplastic to be infused through the preform as the matrix system and becomes an integral element of the finished part. This method potentially allows the manufacture of recyclable, thermoplastic composite materials with extremely reduced manufacture times compared to the industry standard, opening the door for mass adoption into areas such as the automotive industry.
The feasibility of this new approach is investigated, with detailed research into aspects of ‘forming’, ‘transport’, ‘infusion’, and ‘testing’ conducted ahead of a demonstration and discussion on the suitability of the technique to meet its goals. Each shows positive contributions, but ‘transport’ is especially positive since better geometric stability and the easy formation of a vacuum seal between the robot head and the part is possible. In order to test the feasibility of the approach, the creation, characterisation, and development of appropriate testing rigs and high-temperature manufacturing facilities has been required, and this may limit full industrial impact as the set up will need to be replicated and ultimately developed into larger industrially relevant equipment.
| Date of Award | 9 May 2023 |
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| Original language | English |
| Awarding Institution |
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| Supervisor | Ben K S Woods (Supervisor), Ian Hamerton (Supervisor) & Carwyn Ward (Supervisor) |