JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 61

Making thick-section composite components
First main composites research theme
The simple answer to recycling composites lies in the use of
thermoplastic resins as the matrix material, such as PEEK,
polypropylene (PP) derivatives, and high-performance Nylons.
Thermoplastic-based systems have the potential to revolutionise
the sector in this regard, with the prospect of being able to
melt and re-press components without performance implications,
and without the removal of the resin matrix - a characteristic
that has long eluded thermoset CFRPs. Moreover, this
ability to reprocess the material lends itself exceptionally well
to in-situ repair and damage healing. Another critical advantage
of TPCs is their inherent toughness and damage tolerance.
TPCs offer a vision of multi-life components that can be reconditioned
or remanufactured many times over while maintaining
their mechanical properties.
The development of thick-section composites with in-built recyclability
is a central research theme at Exeter.
The only limitation to TPC adoption has been that, until recently,
TPCs (thermoplastic composites) have not been able
to deliver the requisite mechanical performance for structural
applications.
These are now within reach for TPCs, where PEEK/carbon
moulding compounds achieve a bulk modulus of ~40 GPa,
which is a marked improvement over previous offerings and
now rivals equivalent thermosets. Recent advances in manufacturing
approach pioneered by the lab have seen the achievable
modulus reliably pushed above 70 GPa - directly on par with
aluminium.
Second main composites research theme
Exeter has developed a manufacturing technique that allows controlled,
localised fibre orientation through the use of pre‐consolidated
charges. This technique offers control of fibre orientation in
all three axes, an advantage that could revolutionise the TPC sector
where aligned fibre pre-charges could now be used to augment
component properties in the exact areas required, allowing designers
the freedom to exactly specify the size, type, orientation and the
fibre volume-fraction in differing regions of the same component.
Because the pre-charges are pre-made, each pre-charge can have its
own specific formulation, so that where optimised stiffness, tensile
strength, or toughness, for example, is required within a singular
component, these features can be designed-in and easily manufactured.
Figure 3 shows a quarter section of the AW129 helicopter
wheel. The diagram shows how oriented pre-charges have been
used to optimise properties beyond that achievable by an isotropic
monolith. Assembly is simply a matter of arranging the appropriate
pre-charges within the tool, and re-melting and consolidating the
component.
#1
#2
Helicopter wheels and their CT scan
Equipment and facilities
Exeter specialises in PEEK utilisation, its composites, additive manufacturing, recycling and chemistry, where
this expertise and facilities led to a £3M collaboration with Victrex PLC - the world-leading chemical company
producing most of the world's PEEK. Exeter is an internationally recognised centre for PEEK, where the team
organises and hosts the bi-annual industrial colloquium " European Strategy for high temperature AM and PEEK
Composites " . The lab has specialist facilities for processing high-temperature polymers in particular, including injection
moulding, and two state-of-the-art thermoplastic 80-tonne hot presses equipped with rapid cooling. It is
also able to perform all types of mechanical testing and includes a polymer analysis suite (DSC, DMA, thermal
conductivity, melt-flow, porosity, rheometry, CT & SEM) specifically targeting high-performance plastics.
Half caliper
Dr. Luke Savage is a senior materials scientist with 24 years' experience of researching answers to real-world industrial
problems. Research areas include:
1) automotive materials engineering - structures, composite electric vehicle systems, specialised materials for
harsh environments;
2) aviation materials engineering - novel applications of thermoplastic composites, under-carriage systems, carbon/carbon
materials;
3) composites - thermoplastic composites, discontinuous composite structures, composite structure design and
failure mechanism analysis;
4) composite recycling approaches;
5) tribology - carbon/carbon brake materials, lightweight braking system design and manufacture, high-performance
automotive braking systems. Dr Savage has won numerous funding awards, all of which involve extensive
industrial support and collaboration, and typically, research programmes of several years' duration.
More information:
http://emps.exeter.ac.uk/engineering/research/etg/
N°142 September - October 2021 / jec composites magazine
61
http://emps.exeter.ac.uk/engineering/research/etg/

JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021

Cover
Edito
«Manufacturers have realized they must increase their flexibility and resilency»
Contents
NEWS
In brief
Agenda
Productivity - Record turnaround secures major thermopress order
BUSINESS
Startup - Skyroot Aerospace: the story of young space enthusiasts from India
Matrix - Commercial bio-based resins for composites
Natural fibre - The reality of today’s natural fibre markets and research paving the way to valorization (Part 2)
MANUFACTURING
Resin - Application characteristics of epoxy foam
TFP - High-performance polymers for fibres and fibre-reinforced composites
FEATURE AUTOMOTIVE: Lighter, stronger, greener?
- Structural performance - Jointly conducted analysis and structural test evaluation for automotive B-pillar parts
- Market - Composites innovation in U.S. commercial trucks and vans
- Industry - The importance of lightweight construction for the automotive industry
- Body in white - First Composite intensive multi-material BiW structure made in/for China
- Sustainability - Green composite perspectives for semi-trailers
SOLUTIONS
Industrial equipment - The Massivit 10000 cuts production timelines drastically. Instead of weeks, it takes days
Building and construction - Enhancing construction with composites
TECHNOLOGY
Thermoplastics - Holistic optimization of the high-speed tape lay-up process using a digital twin
Augmented-reality - lmproved manual composite manufacturing with an augmented-reality system
Inside the lab - Making thick-section composite components
Index
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JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Cover
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 2
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Edito
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - «Manufacturers have realized they must increase their flexibility and resilency»
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 5
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Contents
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 7
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - In brief
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 9
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Agenda
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Productivity - Record turnaround secures major thermopress order
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 12
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Startup - Skyroot Aerospace: the story of young space enthusiasts from India
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 14
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 15
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Matrix - Commercial bio-based resins for composites
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 17
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Natural fibre - The reality of today’s natural fibre markets and research paving the way to valorization (Part 2)
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 19
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 20
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Resin - Application characteristics of epoxy foam
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 22
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - TFP - High-performance polymers for fibres and fibre-reinforced composites
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 24
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 25
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 26
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - - Structural performance - Jointly conducted analysis and structural test evaluation for automotive B-pillar parts
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 28
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 29
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - - Market - Composites innovation in U.S. commercial trucks and vans
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 31
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 32
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 33
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 34
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - - Industry - The importance of lightweight construction for the automotive industry
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 36
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 37
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 38
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - - Body in white - First Composite intensive multi-material BiW structure made in/for China
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 40
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 41
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 42
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 43
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - - Sustainability - Green composite perspectives for semi-trailers
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 45
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 46
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 47
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Industrial equipment - The Massivit 10000 cuts production timelines drastically. Instead of weeks, it takes days
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 49
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Building and construction - Enhancing construction with composites
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 51
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 52
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Thermoplastics - Holistic optimization of the high-speed tape lay-up process using a digital twin
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 54
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 55
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 56
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 57
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Augmented-reality - lmproved manual composite manufacturing with an augmented-reality system
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 59
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Inside the lab - Making thick-section composite components
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 61
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 63
JEC COMPOSITES MAGAZINE - Issue #142 - September/October 2021 - 64
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