• Lufahrtforschungs-programm 6-1
  • 2020 - 2022

NICItA

Nonwoven Infusion for Composites as Impact tolerant Aviation-Structures

(nur auf Englisch verfügbar)

Motivation

The high energy consumption and process costs associated with prepreg autoclave have motivated us to explore alternative manufacturing methods. Resin transfer molding (RTM) is a promising candidate with its potential for producing high-quality parts while being more cost-effective and environmentally friendly. By investigating and optimizing the RTM process parameters and materials selection, we aim to develop a more efficient and sustainable manufacturing method that can enhance the quality and reliability of the final products.

Projektdetails

Felix Teichmann, M.Sc.
ITA Augsburg (Composites)

2020 – 2022

gefördert durch:
Lufahrtforschungs-programm 6-1

Budget: – €


Objective

Our objective is to develop a multi-component non-woven material that can improve the resin transfer molding (RTM) process in several ways. First, we aim to incorporate binder functionality into the non-woven material, eliminating the need for additional binder materials. Second, we plan to include infusion functionality in the non-woven material to enable a faster and more stable process. Finally, we aim to enhance impact properties of the final product through the inclusion of an interleaf-layer, resulting in an improved overall product quality. By achieving these objectives, we hope to contribute to the development of more efficient and cost-effective manufacturing methods, while also improving the performance and quality of the final products.

Manufacturing

Our goal in manufacturing is to produce homogenous non-woven materials with a low areal weight of 20-40 gsm. To achieve this, we follow a workflow that begins with fibre mixing and preparation, ensuring even distribution of the different fibre types. Next, we use a carding machine to produce homogenous non-woven fabrics, which are then wound and stored. The final step involves thermal consolidation, which improves the handling and infusion functionality of the material.

Figure A. Schematic representation of the carding machine

Figure B. Different non-woven qualities (l) bad quality (m) improved quality (r) good quality

Table 1. Combinations V1-V4 with different material blends and areal weights were produced and tested

Project results

Binder & Performing

In our results, we found that K140 is a superior binder material compared to Cetex due to its different melting characteristics. We also observed that preform temperature has a significant impact on the results, and a higher share of binder materials leads to improved preform stability. Shown in Figures C and D.

Figure C. Non-woven fabrics integrated between the NCF layers

Figure D. Comparison between two preforming experiments

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