Consolidation of Thermoplastic hybrid yarn materials

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This proposal addresses the topic of Consolidation of Thermoplastic hybrid yarn materials -ConThP, consisting of thermopl astic matrix fibres and reinforcing carbon fibres. The ConThP project is about the implementation of a consolidation approach into finite element analysis which enables to use hybrid yarn materials in conjunction to complex toolings to enable integral design concepts with a high structural performance.The objective is to develop a constitutive 3D approach which considers air evacuation, fibre bed compaction, resin flow and void formation in a model suitable for application in finite element analysis. This model will cover high performance thermoplastic material and is applicable for load carrying aerospace structures. The results will support the phase of design and process development and create opportunities for an efficient manufacture of complex shaped high performance fibre reinforced thermoplastics from hybrid textiles.Considering consolidation within the design process will allow applying knowledge based procedures, which will reduce development time and costs in the production of composite parts. Furthermore, using a consolidation prediction rather than empirical based rules allows an increased flexibility in the part design. The integrative consolidation model will be validated by the manufacture of a complex shaped component.