Session: 03-11-01: Thermoplastic Composites

Paper Number: 136402

136402 - Characterization of Thermoplastic In-Situ Consolidation & Post-Processing: Interlayer, Intralayer, and Fiber-Matrix Adhesion 

Thermoplastic composites (TPCs) are of significant interest for the next generation of large-scale aerostructures, owing to their toughness, recyclability, and rapid processing capabilities. Additionally, the ability to weld TPCs can substantially reduce manufacturing time and cost by eliminating the need for fastened joints. In-Situ Consolidation with Automated Fiber Placement (ICAT) presents a promising manufacturing workflow for producing large-scale TPC components. This presentation will conduct a comprehensive analysis of interlayer, intralayer, and fiber-matrix adhesion behaviors of ICAT laminates compared to compression molded laminates. The evaluation encompasses differential scanning calorimetry and micro-CT results for crystallinity and porosity across manufacturing techniques. Qualitative assessments of bonding behavior will be presented using non-destructive evaluation scans. Intralayer characterization includes tensile, compression, and off-axis shear, while interlayer properties will be explored through Short-beam strength, Mode I, and Mode II fracture testing. Fiber pushout tests will further contribute to understanding fiber-matrix adhesion. The key takeaway from the presentation is a deeper understanding of the underlying physics governing the measured characteristics, particularly the significance of intimate contact and interdiffusion development prior to solidification. The influence of crystallization on chain motion, matrix ductility, and fiber-matrix adhesion will be emphasized.

Presenting Author: Joseph Kirchhoff The University of Texas at Austin (Walker, Oden)

Presenting Author Biography: I am a Ph.D. student in the Walker School of Mechanical Engineering where I am co-advised by Dr. Omar Ghattas and Dr. Mehran Tehrani. Funded by a NASA NSTGRO fellowship, I am interested in developing industry 4.0 tools for composites manufacturing. Specifically, the technology I aim to enhance with computational tools is In-Situ Consolidation of Thermoplastic Composites (ICAT). ICAT has potential to be both a high-rate and sustainable approach. I balance my time running experiments in a lab and programming computational methods. Some key areas of interest are: bayesian inverse problems, uncertainty quantification, smart manufacturing, digital twins, fiber composites, solid mechanics, and materials characterization.