Title: Process Analysis of Manufacturing Thermoplastic Type-IV Composite Pressure Vessels with Helical Winding Pattern

Authors: Martin Schäkel, Henning Janssen, Christian Brecher

DOI: 10.33599/nasampe/s.21.0557

Abstract: transportation of hydrogen due to their extraordinary lightweight characteristics. Thermoset CPVs are the market standard due to easy and reliable production. The use of thermoplastic composites for CPV manufacturing via laser-assisted tape winding presents advantages with regard to out-of-autoclave and clean processing, recyclability and design freedom concerning the winding layup. The complex interactions of multiple process parameters like laser power, irradiation incidence angle and tape feed rate along the winding path influence the bonding quality within the composite laminate and require a thorough understanding, especially for helical winding patterns covering cylinder and dome parts of the pressure vessel. In this work, helical circuits of composite tape were placed on a thermoplastic liner with systematically varied process parameters. The temperature distribution governing the bonding quality between the tape plies was monitored and processed for data analysis. An empirical model characterizing the influences of process parameters on the nip point temperature was created highlighting differences in temperature variation on cylinder and dome parts. Tape feed rate profiles were also taken into account to identify action fields for the development of an optimized process for thermoplastic CPV manufacturing.

References: [1] Sachgau, O. & Behrmann, E. “The Hydrogen-Powered Car’s Big Setback.” Bloomberg. March 23, 2018. <https://www.bloomberg.com/news/articles/2018-03-23/the-hydrogen-powered-car-s-big-setback> [2] James, B.D., Houchins, C., Huya-Kouadio, J.M. & DeSantis, D.A. “Final Report: Hydrogen Storage System Cost Analysis.” United States Department of Energy. September, 2016. DOI: 10.2172/1343975. [3] Red, Chris. “Pressure vessels for alternative fuels, 2014-2023.” Composites World. January 12, 2014. <https://www.compositesworld.com/articles/pressure-vessels-for-alternative-fuels-2014-2023> [4] Holmes, Mark. “High volume composites for the automotive challenge.” Reinforced Plastics 61(5) (2017): 294-298. DOI: 10.1016/j.repl.2017.03.005. [5] Romagna, Jürg Herbert. “Neue Strategien in der Faserwickeltechnik.” Dissertation ETH Zürich, 2017. DOI: 10.3929/ethz-a-001945867. [6] Mallick, P.K. “Fiber-reinforced Composites.” Boca Raton, United States: CRC Press, 2007. [7] Mazumdar, Sanjay K. “Composites Manufacturing – Materials, Product and Process Engineering,” Boca Raton, United States: CRC Press, 2000. [8] Steyer, Martin. “Laserunterstütztes Tapelegeverfahren zur Fertigung endlosfaserverstärkter Thermoplastlaminate.” Dissertation RWTH Aachen, 2013. [9] Villalonga, A., Thomas, C., Nony, F., Thiebaud, F., Geli, M., Lucas, A., Kremer-Knobloch, K. & Maugy, C. “Application of full thermoplastic composite for Type IV 70 MPa high pressure vessels.” Proceedings of 18th International Conference on Composite Materials. Jeju Island, South Korea, August 21-26, 2011. The Korean Society of Composite Materials. [10] Kollmannsberger, Andreas M. “Heating characteristics of fixed focus laser assisted Thermoplastic-Automated Fiber Placement of 2D and 3D parts.” Dissertation TU München, 2019. [11] Kermer-Meyer, Alexander. “Formhaltige and komplexe Laminatstrukturen in Thermoplast-Tapelegeverfahren.” Dissertation RWTH Aachen, 2015. [12] Brecher, C., Werner, D. & Emonts, M. “Multi-Material-Head – One tool for 3 technologies: Laser-assisted thermoplast-tape placement, thermoset-prepreg-placement and dry-fiber placement.” Proceedings of the 20th International Conference on Composite Materials. Copenhagen, Denmark, July 19-24, 2015. MCI Copenhagen.

Conference: SAMPE NEXUS 2021

Publication Date: 2021/06/29

SKU: TP21-0000000557

Pages: 13

Price: FREE