48″溶液法织物预浸机工艺稳定性研究

着重比较了不同批次预浸料的性能，进而评价了４８″溶液法织物预浸工艺稳定性。为批量生产质量合格的预浸料提供了依据。     

JFY－1静电粉末预浸设备EI

介绍了ＪＦＹ－１静电粉末预浸机的结构特点及工艺过程，列出了设备主要参数。     

预聚工艺对3233树脂基复合材料性能的影响

介绍了3233树脂体系用预聚体的批次稳定性，对比了小批量和放大合成 预聚体所制备的复合材料性能。     

PEEK基体热塑性树脂基复合材料的研究

介绍了热塑性树脂基复合材料用ＰＥＥＫ树脂的性能，静电粉末法制备热塑性树脂预浸料的设备和工艺，用该工艺制备的预浸料规格和性能以及ＡＳ４Ｃ单向织物／ＰＥＥＫ复合材料的力学性能，韧性，耐环境性能，同时还介绍了将这种材料用于宇航工业而进行的基础研究工作。     

PMR—1及其复合材料的发展与应用

综述了耐高温聚酰亚胺ＰＭＲ－１５的组成及化学性能，预浸料及复合材料的制造、性能及应用，并对ＰＭＲ－１５的发展情况作了介绍。     

热熔胶膜法制造预浸料对复合材料力学性能的影响

讨论了热熔胶膜法制备了３２３４／Ｇ８０３ＰＶ预浸料对其复合材料弯曲强度，弯曲模量和层间剪切强度及其保持率的影响，指出使用热熔法制备预浸料可以提高复合材料的耐湿热性。     

碳织物／PEEK静电粉末预浸工艺树脂含量检测控制系统

介绍了一种由β射线检测仪、微机等组成的碳织物／ＰＥＥＫ（聚醚醚酮）静电粉末预浸过程树脂含量动态监控系统。该系统能够跟踪预浸过程，准确、灵敏地反映树脂含量的变化，并能根据要求及时调整工艺参数，保证预浸料树脂均匀分布，有利于工艺过程的连续化、自动化。本文介绍了这种监控系统的组成及工作原理，绘出了一些预浸料的工作曲线，考察了这种控制系统的性能，验证了其可行性。     

纤维增强热塑性树脂预浸料的制备工艺及研究进展

热塑性复合材料因冲击韧性高、环境适应性强、可回收利用等优点,被广泛应用于汽车制造、航空航天、国防军工等领域。但因热塑性树脂加热熔融后较高的黏度使其很难与纤维充分浸渍。预浸料作为制造复合材料的中间材料,现阶段制备工艺已相对成熟,预浸料中纤维已被树脂浸润,因此通过预浸料制备的复合材料孔隙率较低。本文介绍了现阶段常用的热塑性预浸料制备方法及各自的优缺点,包括溶液浸渍法、熔融浸渍法、粉末浸渍法、薄膜叠层法、纤维混杂法以及反应链增长浸渍法。阐述了热塑性树脂熔体浸润纤维的浸渍机理,对浸渍机理的部分研究成果进行了概括。概述了浸渍温度、浸渍压力和牵引速率对预浸带性能的影响。最后指出了国内预浸料生产中存在的主要问题,未来可采用多学科结合、纤维树脂改性、对浸渍过程进行计算机模拟等方法促进热塑性预浸带的产业化发展。     

悬浮法制备PPS／CF复合材料

采用ＰＳＳ粉粒，二苯醚，酮制成一家配比的乳浮液，与连续碳纤维浸渍，以点加热方式去除溶剂，熔融ＰＰＳ粉粒，获得ＰＰＳ／ＣＦ预浸带，并压制成单向复合材料。通过电镜、短梁剪试验和断裂韧性测试，对预浸料和复合材料进行了质量评定。     

新型耐高温马来酰亚胺基体树脂的研制EI

本文报道一种新型耐高温马来酰亚胺基体树脂的合成方法，并对其进行了红外表征，热重分析测试。该树脂合成工艺较为简便，而且有良好的溶液性，可用丙酮作溶剂制造预浸料。     

A simulation study on the effects of particle size on the consolidation of polymer powder impregnated tapes

The powder prepreg technique offers a low-cost, high-speed method of manufacture of composites. Consolidation of the prepreg tows is a key step in the manufacture of a final `useful' part. The efficiency of the consolidation for any polymer powder prepreg tape produced from powder prepreg processes would conceivably depend on the material properties of the polymer, particle size, temperature, consolidation pressure and volume fraction of the tape. A mathematical process model that identifies and describes a set of parameters to predict the consolidation conditions of a given polymer powder prepreg tape has been developed. A simulation study that identifies the different parameters and compares the advantages and limitations of polymer physical properties and particle size has been performed. An integrated Flow Resistance (FR) index has been developed to mathematically describe the consolidation process. The results show that small powder particle sizes are beneficial to the process.     

A process model for the compaction and saturation of partially impregnated thermoset prepreg tapes

Automated manufacturing of composite materials is key to reducing cost and improving consistency in part quality. Modeling of manufacturing processes can identify influential material, geometric, and process variables, while providing a framework for their optimization and control. A process model has been formulated to describe the compaction and saturation of partially impregnated thermoset prepreg tapes during their placement, using a roller compaction and vacuum consolidation. The roles of various parameters that characterize the initial prepreg tape state and the final prepreg tape state are investigated. The model yields the degree of resin saturation in the tape with changes in its thickness after being compacted, due to an external pressure. The results estimate the degree of dry fiber region within the tape, which can provide vacuum pathways for air or volatile removal before consolidation and cure. The model can be adapted for different material constitutive relationships of tape compaction and saturation.     

On-line consolidation of thermoplastic composites using laser scanning

A novel technique to process thermoplastic composites by laser-assisted tape winding has been developed and evaluated. Previous investigations were limited to a stationary beam and consolidation of narrow prepreg tapes. The technology was extended to process wider prepreg tapes using a galvanometer-based scanning system. The energy distribution along the consolidation line is affected by the triggering signal used to position the scanning mirror. This distribution is predicted using a geometrical model and the results are confirmed experimentally with imprints of the scanned beam in Plexiglas. It was found that the most homogenous heating of the surface is achieved if a triangular triggering signal is used. Density and short beam shear tests are used to evaluate the bond quality that can be achieved using the beam scanning system in comparison to parts fabricated with a stationary beam. Tests have been performed on parts processed with different laser power settings and scanning frequencies. The shear strength increases with increasing laser power to an optimum value after which it decreases due to the degradation of the thermoplastic matrix. The scanning frequency in contrast had no influence on the shear strength. The possibility to process wider tapes using the scanning system was demonstrated by consolidating a one-inch wide PPS/Carbon prepreg tape.     

The experimental determination of prepreg tack and dynamic stiffness

A new peel test has been developed which quantifies the tack and dynamic stiffness of uncured prepreg. The test is designed to simulate the automated tape lay-up (ATL) and automated fibre placement (AFP) processes. It includes a pressure controlled application stage, where contact time is inversely proportional to peel rate. The use of a thin film allows stiffness to be isolated from peel resistance in a continuous two stage test. A repeatability study revealed consistent results with 16% standard deviation. Tack and stiffness variability has been observed across roll width and between faces in commercial hand lay-up prepregs. The overall tack and stiffness values for commercial hand lay-up prepregs were found to be inconsistent with the levels specified by manufacturers.A temperature increase revealed inconsistent effects on tack between materials. The contradictory results were rationalised by observing failure modes. The two failure modes observed appeared equivalent to those found in pressure sensitive adhesive (PSA) peel. The shear storage modulus of the prepreg resin was compared to the PSA Dahlquist criterion and found to support the principle of contact efficiency. However, the actual value for the criterion is expected to be a function of prepreg specific conditions such as resin content, fibre distribution and surface pattern.     

Modeling and Simulation of Voids in Composite Tape Winding Process Based on Domain Superposition Technique

The tape winding technology is an effective way to fabricate rotationally composite materials. Nevertheless, some inevitable defects will seriously influence the performance of winding products. One of the crucial ways to identify the quality of fiber-reinforced composite material products is examining its void content. Significant improvement in products’ mechanical properties can be achieved by minimizing the void defect. Two methods were applied in this study, finite element analysis and experimental testing, respectively, to investigate the mechanism of how void forming in composite tape winding processing. Based on the theories of interlayer intimate contact and Domain Superposition Technique (DST), a three-dimensional model of prepreg tape void with SolidWorks has been modeled in this paper. Whereafter, ABAQUS simulation software was used to simulate the void content change with pressure and temperature. Finally, a series of experiments were performed to determine the accuracy of the model-based predictions. The results showed that the model is effective for predicting the void content in the composite tape winding process.     

Residual stress distribution in carbon fibre/thermoplastic matrix pre-impregnated composite tapes

The distribution of residual strain in carbon fibre (P75) reinforced thermo-plastic (polyetheretherketone, PEEK) composites has been studied by monitoring the Raman frequencies of the embedded carbon fibres at the microscopic level. The average longitudinal strain in the fibre measured in a 100 mm² section of a P75/PEEK prepreg was found to be compressive and comparable in magnitude to residual strain values computed analytically. The combined effects of differential thermal expansion of the two materials, differences in fibre size and in the thickness of resin layer, are offered as likely explanations for the incurred variations in the Raman frequency values and the considerable spread of the fibre Raman frequency distribution in the prepreg tape. Finally, it is demonstrated that the previously reported high values of apparent compressive strain in similar composite tapes by means of Raman spectroscopy were artefacts of the experimental procedure.     

碳纤维/环氧树脂复合材料-铝合金层合板深拉成型特性

碳纤维增强树脂复合材料（Carbon fiber reinforced plastic,CFRP）因其轻质高强的特点,越来越多地应用到汽车轻量化设计和制造中。为研究CFRP板件及CFRP-Al层合板深拉成型影响因素,加速CFRP零部件产业化进程,本文通过DSC测试分析了CFRP预浸料的固化放热过程,以此为依据,用热压罐制备了不同后固化温度下成型的CFRP板材及单向、编织两种预浸带铺层的CFRP-Al层合板,用Inspekt table 100材料试验机对上述两种板材分别做了深拉试验。考虑到提高制备效率,用打磨、打磨+涂覆硅烷偶联剂、阳极氧化+涂覆硅烷偶联剂三种方式对铝合金板进行表面处理,不经热压罐固化成型,直接和正交对称铺层的单向预浸带一起在Inspekt table 100材料试验机的环境箱中混合温深拉,固化成形。并通过金相显微镜、SEM进行显微组织观察,验证后固化温度、深拉环境温度、预浸带的种类对CFRP板材及CFRP-Al层合板深拉成型性能的影响及铝合金板表面处理方式对CFRP叠层预浸带、铝合金板材混合温深拉成型性能的影响。结果表明,适当降低后固化温度、提高深拉环境温度有利于板材二次深拉成型。编织预浸带较单向预浸带能更好地承受压力,深拉成型质量更优。阳极氧化+涂覆硅烷偶联剂的表面处理方式一方面能在铝合金板材表面形成致密、均匀的微孔,另一方面硅烷偶联剂能很好地促进铝合金板材和CFRP的界面结合,有利于深拉成型。      

A method for the direct measurement of the fibre bed compaction curve of composite prepregs

A method to measure the fibre bed compaction curve directly from composite prepreg is presented. The method was used to measure the compaction curve of unidirectional and quasi-isotropic AS4/3501-6 carbon–epoxy prepregs. Similar compaction curves were obtained in all cases. The compaction curve obtained was used by a finite element process model, COMPRO, to simulate the uniaxial compaction of 8 and 16 ply laminates at different temperatures. The force–displacement response predicted by the model closely matched the experimental results. The method which can be used on both tape and fabric prepregs, has the major advantages of being a direct measure of the prepreg behaviour, and requires no special preparation of the sample.     

Low-energy electron beam cured tape placement for out-of-autoclave fabrication of advanced polymer composites

The autoclave curing process for advanced polymer composites is labor and capital intensive, with the curing cost increasing dramatically by the growth in part size. In order to develop an out-of-autoclave (OOA) fabrication process for advanced polymer composites, a new process integrating automated tape placement with low-energy electron beam radiation curing was explored, by which in situ layer-wise curing of advanced composites can be achieved with the tape placement process. The irradiation process was optimized to get a homogenous curing, by tuning the electron beam dose-depth distribution in the prepreg material. Besides, the curing characteristics of the prepreg material by the low-energy electron beam irradiation was investigated and effect of exposure dose and post curing on curing degree, glass transition temperature (Tg) and interlaminar shear strength (ILSS) were characterized experimentally.     

基于灰色关联分析和响应面法的复合材料缠绕成型多目标工艺参数优化

针对复合材料预浸带缠绕过程中制品的残余应力、孔隙率最小化和层间剪切强度（ILSS）最大化的多目标优化问题,采用Box-Behnken Design （BBD）原理设计四因素三水平的T300/环氧树脂预浸带缠绕实验;基于灰色关联分析（GRA）将多目标优化问题转化为单目标优化问题,利用主成分分析（PCA）法确定残余应力、孔隙率和ILSS对灰色关联度（GRG）的影响权重;通过对实验数据的回归分析,建立GRG与主要缠绕工艺参数（缠绕温度、张力、压辊压力和缠绕速度）的二阶预测模型;分析了各工艺参数对残余应力、孔隙率、ILSS和GRG的影响规律,确定缠绕工艺参数优化方案;利用响应面法（RSM）求解工艺参数优化问题并进行复合材料预浸带缠绕实验。结果表明:该优化方法获得的最优工艺参数组合可以有效改善残余应力、孔隙率和ILSS,提高预浸带缠绕制品的性能。