Research Initiation Award: In-situ Impregnation of Polymers and Ceramics in Composites Manufacturing

小行星9308498 热塑性基质纤维部件主要使用中间材料形式（例如，纤维条、带或丝束浸渍体）来制造，这降低了制造和设计灵活性，并且增加了产品成本。 即使是以粉末形式合成的树脂也可以转化为粒料并熔融浸渍在玻璃纤维上以制造短纤维复合材料。 从制造时间、加工和设计灵活性以及能量考虑来看，用于制造最终部件的若干加工步骤是浪费的。 本研究的主要目的是开发一种单一的连续工艺， 在连续纤维中浸渍和固结聚合物粉末以将部件制造成净形状。 该方法扩展到在连续纤维上用聚合物粉末封装陶瓷粉末。 浸渍是通过静电喷雾沉积和粘附到纤维丝束、快速加热和在长丝缠绕或制浆工艺中固结来完成的。 为每个子过程开发过程模型，并在过程开发周期中进行集成。 这一过程的开发和演示将直接导致最大限度地减少加工步骤和降低相关成本。 该工艺可用于直接制造用于注塑和挤出工艺的纤维缠绕、拉挤部件和树脂封装玻璃纤维。 陶瓷粉末包封丝束可用于制造连续纤维陶瓷复合材料和在摩擦学情况下具有陶瓷颗粒作为填料的复合材料。

9308498 Ramani Thermoplastic matrix fiber components are predominantly manufactured using intermediate material forms such as prepregs, tapes or towpregs, which reduces manufacturing and design flexibility, and increases the product costs. Even resins that are synthesized in powder form are converted to pellets and melt impregnated on glass fibers to manufacture short fiber composites. Several processing steps for the manufacture of the final component are wasteful from both manufacturing time, processing and design flexibility, and energy considerations. The primary objective of this research is to develop a single continuous process for impregnating and consolidating polymeric powders in continuous fibers to manufacture components to net shape. This process is extended to encapsulate ceramic powder with polymeric powder on continuous fibers. The impregnation is accomplished by electrostatic spray deposition and adhesion to the fiber tow, rapid heating, and consolidation in a filament winding or pultrusion process. Process models are developed for each sub-process and integrated during the process development cycle. Development and demonstration of this process will directly lead to minimizing the processing steps and reducing the associated costs. This process can be used for direct manufacture of filament wound, pultruded components and resin encapsulated glass fibers for injection molding and extrusion processes. Ceramic powder encapsulated tows can be used for the manufacture of continuous fiber ceramic composites and composites with ceramic particles as a filler in tribological situations.