Induction Consolidation of Thermoplastic Composites Using Smart Susceptors
This project has focused on the area of energy efficient consolidation and molding of fiber reinforced thermoplastic composite components as an energy efficient alternative to the conventional processing methods such as autoclave processing. The expanding application of composite materials in wind energy, automotive, and aerospace provides an attractive energy efficiency target for process development. The intent is to have this efficient processing along with the recyclable thermoplastic materials ready for large scale application before these high production volume levels are reached. Therefore, the process can be implemented in a timely manner to realize the maximum economic, energy, and environmental efficiencies. Under this project an increased understanding of the use of induction heating with smart susceptors applied to consolidation of thermoplastic has been achieved. This was done by the establishment of processing equipment and tooling and the subsequent demonstration of this fabrication technology by consolidating/molding of entry level components for each of the participating industrial segments, wind energy, aerospace, and automotive. This understanding adds to the nation's capability to affordably manufacture high quality lightweight high performance components from advanced recyclable composite materials in a lean and energy efficient manner. The use of induction heating with smart susceptors is a precisely controlled low energy method for the consolidation and molding of thermoplastic composites. The smart susceptor provides intrinsic thermal control based on the interaction with the magnetic field from the induction coil thereby producing highly repeatable processing. The low energy usage is enabled by the fact that only the smart susceptor surface of the tool is heated, not the entire tool. Therefore much less mass is heated resulting in significantly less required energy to consolidate/mold the desired composite components. This energy efficiency results in potential energy savings of {approx}75% as compared to autoclave processing in aerospace, {approx}63% as compared to compression molding in automotive, and {approx}42% energy savings as compared to convectively heated tools in wind energy. The ability to make parts in a rapid and controlled manner provides significant economic advantages for each of the industrial segments. These attributes were demonstrated during the processing of the demonstration components on this project.
- Research Organization:
- The Boeing Company
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE)
- DOE Contract Number:
- FG36-08GO18135
- OSTI ID:
- 1043163
- Report Number(s):
- Final Technical Report Induction Consolidation of Thermoplastic Composites Using Smart Susceptors; TRN: US201214%%107
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
36 MATERIALS SCIENCE
AUTOCLAVES
COMPOSITE MATERIALS
COMPRESSION
ECONOMICS
ENERGY EFFICIENCY
FABRICATION
FIBERS
HEATING
INDUCTION
MAGNETIC FIELDS
MOLDING
PERFORMANCE
POTENTIAL ENERGY
PROCESSING
PRODUCTION
TARGETS
THERMOPLASTICS
Thermoplastic Composites
Induction Welding of Thermoplastics
Energy Consumption
Induction Heating
Smart Susceptors
Polypropylene
Nylon
PEKK
Thermoplastic Composites Molding
Thermoplastic Composites Consolidation