High Volume Manufacture and Inspection Processes for Composite Pipes

热塑性复合材料因其韧性、易于回收以及无需高压灭菌器即可大批量生产的特点，正逐渐取代传统的热固性材料。复合管大批量制造和检验工艺项目旨在开发新的制造和检验工艺，以生产具有成本效益的热塑性复合管，并对材料进行全面鉴定。联盟由Sigma Precision Components(Lead)、Pultrex、激光光学工程和曼彻斯特大学组成。该项目将开发一种拉挤工艺来制造高质量的热塑性复合管，并开发一种半自动激光剪切成像检测系统来检查缺陷。这种碳/热塑性材料也将是第一批完全用于航空航天的材料之一。合作伙伴将需要确保这些工艺能够在保持产品质量的同时实现成本和生产率目标。Sigma是一家金属航空航天管组件制造商，并已开发出可用于轻型管组件和扭力轴的热塑性复合管技术。为了充分利用市场机会，Sigma将实施一系列工作方案，通过一系列优惠券测试完全合格热塑性复合材料(由NCAMP监督和发布)。目前，在行业复合材料手册17中公布的热塑性复合材料很少。此外，管材的制造成本需要降低，通过另外两个工作包来解决。虽然拉挤是制造各种热固性复合材料型材的成熟技术，但Pultrex(一家总部位于英国的拉挤设备制造商)将开发创新的解决方案来适应热塑性管材的工艺，特别是加热和冷却系统以及固结模具设计。曼彻斯特大学将协助他们从实验室试点过程中转移知识，并为教学目的保持密切的学术兴趣。Pultrex还预计这种设备在汽车等其他行业的潜在销售。对于第三个工作包，激光光学工程公司将采用他们现有的激光剪切成像系统之一，以检查复合管是否存在夹杂物、孔洞和分层等缺陷。该系统将使用特殊的激光、相机和半自动图像分析来检查管子，速度比传统的C扫描技术更快。他们的创新将专注于将一种坚固耐用的系统微型化，既可用于工业用途，也可用于在维修期间检查飞机上的复合材料结构，甚至是风力涡轮机叶片。

Thermoplastic composites are gaining favour in place of traditional thermoset versions for their toughness, ease of recycling and ability to be manufactured in high volume without autoclaves. The High Volume Manufacture and Inspection Processes for Composite Pipes project aims to develop novel manufacturing and inspection processes for production of cost-effective thermoplastic composite tube, and to fully qualify the material.The consortium comprises Sigma Precision Components (lead), Pultrex, Laser Optical Engineering and University of Manchester. The project will develop a pultrusion process to make high-quality thermoplastic composite tube and a semi-automatic laser shearography inspection system to check for flaws. The carbon /thermoplastic material will also be one of the first to be fully characterised for aerospace use. The partners will need to ensure the processes are capable of achieving cost and productivity targets while maintaining product quality.Sigma is a manufacturer of metallic aerospace pipe assemblies and has developed thermoplastic composite tube technology that can be used for lightweight pipe assemblies and torque shafts. To fully capitalise on market opportunities, Sigma will perform a work package to fully qualify the thermoplastic composite material (overseen and published by NCAMP) through a series of coupon tests. Currently there are very few thermoplastic composites published in the industry's Composite Materials Handbook 17. In addition, the manufacturing costs for the tube need to be reduced, addressed by the two other work packagesAlthough pultrusion is an established technology for making various thermoset composite sections, Pultrex (a UK based manufacturer of pultrusion equipment) will develop innovative solutions to adapt the process for thermoplastic tubes, in particular the heating and cooling systems and consolidation die design. University of Manchester will assist by transferring knowledge from their laboratory pilot process, and maintain close academic interest for teaching purposes. Pultrex also anticipates potential sales of this equipment in other sectors such as automotive.For the third work package, Laser Optical Engineering will adapt one of their existing laser shearography systems to inspect composite tubes for flaws such as inclusions, porosity and delamination. The system will use special lasers, cameras and semi automatic image analysis to inspect the tube more quickly than traditional C scanning techniques. Their innovation will focus on miniaturising a rugged system for both industrial use and for inspecting composite structures on aircraft during maintenance, or even wind turbine blades.