• Composites Research
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• v.32 no.5
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• pp.229-236
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• 2019

In this study, the effects of the additional processing parameters on the mechanical properties of thermoplastic composites fabricated with automated fiber placement (AFP) were evaluated. Annealing and vacuum bag only processes were then performed on the manufactured thermoplastic composites, respectively. For verification, the crystallinity was measured by differential scanning calorimetry (DSC), confirming the variation of semi-crystalline thermoplastic composite according to the process conditions. The void content of thermoplastic composites was evaluated by matrix digestion method while microscopic examination confirmed the porosity distribution. The interlaminar shear strength test was conducted for three different process parameters (VBO, annealing, and no treatment). A comparison of the three tested strengths was made, revealing that the porosity value had larger effect on the mechanical properties of the thermoplastic composite compared to the degree of crystallinity. Additionally, when thermoplastic composite melted up, the pores were continuously removed under vacuum process; the removal of the pores resulted in an increase of the interlaminar shear strength.

• Composites Research
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• v.34 no.6
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• pp.421-425
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• 2021

In this study, thermoplastic composites were manufactured using a thermoplastic resin (PEEK) with the same melting temperature and a highly heat-resistant carbon UD tapes with different carbon fibers (Type A, Type B). And the bonding characteristics and mechanical characteristics of each of the two produced thermoplastic composites by induction heating welding were examined. The bonding characteristics and mechanical characteristics of the thermoplastic composites were performed using C-Scan and B-Scan, which is a non-destructive inspection, and the single lap shear test, respectively. The temperature of the carbon composites surface was monitored using a thermal image camera.

• Composites Research
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• v.32 no.6
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• pp.360-367
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• 2019

In order to apply thermoplastic composites using PETG resin to various industrial fields such as bicycle frames and industrial parts, it is necessary to verify the impact resistance, durability, mechanical properties and 3D analysis of the manufactured composite materials. To improve the mechanical properties, durability and impact resistance of PETG resin, an amorphous resin, in this study, compound and injection molding process were carried out enhanced various weight percent POE(polyolefin elastomer). The thermal and mechanical properties of the thermoplastic composites, and the charpy impact strength, The analysis was performed to evaluate the characteristics according to weight percent of POE. Charpy impact strength test was conducted to analyze the impact characteristics, and the fracture section was analyzed after the impact strength test. In the case of POE material-added thermoplastic composites, thermal and mechanical properties tend to decrease, but workability and impact resistance tend to be superior to those of PETG materials.

• Composites Research
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• v.36 no.5
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• pp.321-328
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• 2023

This study developed the in-situ stamp-forming process using the multi-axis robotic arm to fabricate thermal composite parts. Optimal fabrication parameters with the multi-axis robotic arm were determined using finite element analysis and these parameters were further refined through the practical manufacturing process. A comparison between the manufactured parts and finite element analysis results was conducted regarding thickness uniformity and wrinkle distribution to confirm the validity of the finite element analysis. Additionally, to evaluate the formability of the manufactured composite parts, measurements of crystallinity and porosity were taken. Consequently, this study establishes the feasibility of the In-situ stamp-forming consolidation using a robotic arm and verifies the potential for producing composite parts through this process.

• Composites Research
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• v.34 no.5
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• pp.296-304
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• 2021

This study presented the evaluation of the stamp forming process for L-shape CF/PEKK thermoplastic composite using the finite element model. The formability of three different trimming allowances has been examined for representative product geometry. The results showed that those manufactured by high trimming allowance showed more excellent formability in those areas. Moreover, the effects of the trimming allowances on the stress, thickness, wrinkle distributions of thermoplastic composites fabricated with the stamp forming process were evaluated. The comparison of the simulation and experimental results for the thickness and wrinkle distributions proved the accuracy of the stamp forming model. The crystallinity of the composite was performed by differential scanning calorimetry (DSC). The void content of the composite was evaluated by matrix digestion. Then, the fabricated structure was characterized and achieved high quality in crystallinity and void content. Consequently, the presented FEM modeling shows excellent potential for application in the aircraft product design process. This pragmatic approach could efficiently offer a valuable solution for the thermoplastic composite manufacturing field.

• Composites Research
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• v.35 no.2
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• pp.86-92
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• 2022

This study was conducted to determine the effect of molecular formation of adhesive on interface characterization of thermoplastic composites. Carbonfiber/polyetherketoneketone (CF/PEKK) thermoplastic composites were fusion bonded and PEEK, PEI adhesive bonded using a high-temperature oven welding process. In addition, lap shear strength test and fracture surface analysis using a digital optical microscope and a scanning electron microscope (SEM), and Fourier transform infrared spectroscopy (FTIR) were performed. As a result, the adhesive bonding method improved adhesion strength with interphase having increased molecular formation of ether groups, ketone groups, and imide groups which mainly constitutes the CF/PEKK and adhesives. Furthermore, it was found that the use of PEEK containing more ether groups and ketone groups forms a more strongly bonded interphase and enhances the adhesive force of the CF/PEKK composites.

• Composites Research
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• v.33 no.6
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• pp.383-389
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• 2020

Thermoplastic composite is introduced to design an automotive door impact beam, and the manufacturing process is demonstrated. The safety regulation for vehicles has been steadily tightened, and weight-reduction has become a mandatory factor in the automotive industry. Hence, both high-performance and lightweight are demanded for automotive components. The aim of the present study is to develop an automotive door impact beam using fiber-reinforced thermoplastic composites to reduce the weight of the impact beam while increasing its mechanical performance. A new production method which combines continuous fiber-reinforced composite and LFT(Long Fiber-reinforced Thermoplastic) is implemented by using insert injection molding process. The mechanical performance of the composite impact beam was evaluated using 3-point bending tests. Thermoplastic composite will expand its application range to various automotive components due to its light-weight design capability and high productivity.

• Composites Research
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• v.35 no.2
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• pp.93-97
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• 2022

The application of infrared heating in the hot press forming of the thermoplastic composites is conducive to productivity with high-speed heating. However, high energy, high forming temperature, and high-speed heating derived from infrared heating can cause material degradation and deteriorate properties such as re-melting performance. Therefore, this study was conducted to optimize the process conditions of the hot press forming suitable for carbon fiber reinforced polyetherketoneketone(CF/PEKK) composites that are actively researched and developed as high-performance aviation materials. Specifically, the degradation mechanisms and properties that may occur in infrared high-speed heating were evaluated through morphological and thermal characteristics analysis and mechanical performance tests. The degradation mechanism was analyzed through morphological investigation of the crystal structure of PEKK. As a result, the size of the spherulite decreased as the degradation progressed, and finally, the spherulite disappeared. In thermal characteristics, the melting temperature, crystallization temperature and heat of crystallization tend to decrease as degradation progresses, and the crystal structure disappeared under long-term exposure at 460℃. In addition, the low bonding strength was observed on the degraded surface, and the bonding surfaces of PEKK did not melt intermittently. In conclusion, it was confirmed that the CF/PEKK composite material degraded at 420℃ in the infrared high-speed heating. Furthermore, the spherulite experienced morphological changes and the re-melting properties of thermoplastic materials were degraded.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.5
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• pp.80-85
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• 2016

Carbon fiber-reinforced composite materials have been widely used in various industrial fields, but there are limits to increasing their strength and stiffness, because of the short-length fibers that are impregnated in them. In this study, a lab-scale small extruder system was developed with the capability to perform the carbon fiber impregnation and extrusion process in order to evaluate the properties of long-length carbon fiber reinforced thermoplastic composite materials molded by the LFT-D method. Specimens were made with the small extruder to press-mold long-length carbon fiber composite materials and evaluate their material properties. As a result, it was found that the carbon fiber length, press load and carbon fiber contents have a considerable influence on the strength and stiffness. Additional studies on such factors as the mixing screw design and coating of the carbon fiber are needed in order to improve the mechanical properties of carbon fiber composite materials.

• Proceedings of the Korean Vacuum Society Conference
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• 2013.02a
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• pp.289-289
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• 2013

CRFP (carbon fiber reinforced plastics)는 탄소섬유 직물에 수지를 함침시켜 만들어지며, 고강도, 고탄성을 지니면서도 가볍고 밀도가 낮기 때문에 항공우주, 스포츠 용품 등 다양한 분야에서 활용되고 있다. 탄소섬유와 수지의 결합력을 증가시키기 위해 사이징, $HNO_3$ 산화, 전기화학적 산화, 플라즈마 처리 등의 다양한 탄소섬유 표면처리 방법이 개발되고 있다. 본 연구에서는 복합재의 강도향상을 위해 탄소섬유 직물을 마이크로웨이브 알곤 플라즈마로 처리하여 강도변화를 관찰하였다. 플라즈마 처리된 직물은 열가소성수지인 CBT와 함침시켜 탄소섬유 복합재로 제조하였다. 그 결과 플라즈마 처리한 복합재의 강도 향상을 확인할 수 있었고, SEM(scanning electron microscope)을 통해 복합재의 표면이 거칠어진 것을 관찰할 수 있었다. 플라즈마로 인해 직물의 표면적이 증가하여 직물의 표면과 수지의 결합력이 증가한 것으로 판단된다.