Co-woven carbon and nylon fibres for manufacturing thermoplastic composite plaques

Thermoplastic composites are in high demand and continually growing in use due to their inherent properties. Commingled fibre is one of the recent solutions developed for thermoplastic composites, but has not yet ready for weaving. An alternative to commingling approach, co-weaving of reinforcing and thermoplastic fibres is investigated in this study. In this work, the carbon and nylon fibres were woven separately through the warp and weft directions, respectively. A 5-multilayer 3D weave architecture was designed to produce the co-woven fabrics. By varying the weft filling or pick density, a set of woven fabrics of different thermoplastic content was obtained. The hot press was used to consolidate the composite plaques. Samples of the thermoplastic composites were physically characterised through density, fibre volume fraction and void content and then optically investigated. The composite samples were also mechanically tested to determine the interlaminar shear strength via the short beam bending test. The result proves that co-weaving method for thermoplastic composites is a feasible approach as the composite shows a low void content of approximately 1.14 percent. Comparing the four co-woven composites tested in this study it is found that the maximum achievable strength (ILSS) is ~ 41.36MPa in the case of lowest matrix (PA66) and the highest fibre (CF) contents, i.e. 13PA/7CF.