Consolidation of hybrid textiles for aerospace applications

Vincent Werlen, Richard Vocke, Christian Rytka, Philip Schwanemann, Véronique Michaud, C.A. Dransfeld

Research output: Chapter in Book/Conference proceedings/Edited volumeConference contributionScientificpeer-review

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Side-by-side hybrid textiles consist of layers of woven reinforcing fibres and thermoplastic fibres fabrics alternatively stacked on each other, as represented in Figure 1. Press moulding of side-by-side hybrid textiles is a manufacturing method where a near-net shape final part is produced in a single step, unlike pre-impregnated materials which require a separate impregnation step. This intermediate material offers a great drapeability and vast design freedom as the hybrid system can be easily and locally modified by changing the textile architecture of a single layer or locally adding a polymer layer for instance. These advantages could be used to locally tailor the composite properties, such as using the full potential of composites to create high-performance parts. However, the prerequisite for such an optimization approach is a consolidation model that can be implemented into a finite element analysis, which is not available yet. We demonstrate the concept's relevance for the aerospace industry by producing and consolidating such a hybrid textile with carbon fibres and polyetherimide into semi-complex shapes. A quasi unidirectional fibre architecture is used for the carbon fibres to keep the properties close to a unidirectional layer, as proved by mechanical characterization. As a first step towards a consolidation model, we develop an impregnation model that considers entrapped air, including dissolution into the polymer melt. The model is validated by consolidating flat plates, which confirm that air entrapment can play a major role in impregnation and needs to be accounted for the prediction of porosity.
Original languageEnglish
Title of host publicationProceedings of the 20th European Conference on Composite Materials: Composites Meet Sustainability
Subtitle of host publicationVol 4 – Modeling and Prediction
EditorsAnastasios P. Vassilopoulos , Véronique Michaud
Place of PublicationLausanne
PublisherEPFL Lausanne, Composite Construction Laboratory
Number of pages8
ISBN (Electronic)978-2-9701614-0-0
Publication statusPublished - 2022
Event20th European Conference on Composite Materials: Composites Meet Sustainability - Lausanne, Switzerland
Duration: 26 Jun 202230 Jun 2022
Conference number: 20


Conference20th European Conference on Composite Materials
Abbreviated titleECCM20


  • Consolidation
  • Hybrid Textiles
  • Carbon fibres
  • PEI
  • Thermoplastic composites


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