Simulations aid novel thermoplastic technologies
Conventional techniques for producing large thermoplastic composite parts for the transport sector consume a great deal of energy. A large energy budget is required for the rapid heating of the mould tools to the correct processing temperature, before suddenly being cooled. The technique is both costly and creates a negative environmental impact. The AMITERM project was a European initiative funded under the GROWTH programme, which developed two novel mould technologies to reduce the amount of energy used. A thermo-chemo-mechanical model was developed for the new JETex process which uses microwave energy to rapidly heat a non-metallic mould. A model was also developed to simulate the new HTex process. The HTex process comprises pre-impregnated 2D or 3D textile inserts made up of hybrid yarn structures. These are pre-positioned in a dedicated mould before undergoing heating and compression. The two technologies enable high speed production with a cycle time of only six minutes compared to 60 minutes for conventional thermoset components. The models were developed by project partners from the Swedish Institute of Composites (SICOMP) and Institute for Fibre and Polymer Research (IFP). The Swedish scientists simulated both the filling process of the moulds and non-Newtonian fluid flow. The team also devised a new technique for ascertaining the thermal contact conductance between metal toolings and composite materials. The resulting data was employed in both the JETex and Htex process simulations. the AMITERM project can help to replace thermoset resins with thermoplastic matrices, which have been improved through the use of JETex and Htex technology. The thermoplastic matrices can be produced more quickly and can increase the lifetime of the parts used. The use of the two new mould technologies combined with thermoplastic resin will also reduce health risks to workers by reducing their exposure to fumes, resin fibre dust and volatiles.
