TheCoS - Thermoplastic Composite Structures

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The aim of the project is to provide a reliable process chain for load-bearing fiber composite structures with thermoplastic matrix, consisting of a component manufacturing process and laser beam welding as connection technology. In order to be able to use fiber composites with thermoplastic plastic matrix, a reliable component manufacturing as well as a suitable connection technology is necessary. For this purpose, the bonding of the reinforcing fibres with a thermoplastic plastic matrix will initially be investigated comprehensively in terms of material science in order to be able to research the process technology for continuous component production using the example of a winding process. The challenge here lies in connecting the impregnated reinforcement fibers with already wound structures, since even small fluctuations in the process temperature can prevent a composite. Therefore, a laser-assisted winding process with integrated process monitoring based on a pyrometric temperature measurement is to be researched. Due to the meltability of thermoplastics, it is advisable to use a welding process as a joining technique. For this purpose, the process technology of laser beam welding is to be researched, with which short process times can be realised and there is a possibility for locally resolved process monitoring. Until now, however, the process is only used for non-fibre-reinforced and short-fibre-reinforced components. The fluctuations in the weld widths already known from preliminary tests, due to the direction-dependent thermal conductivity of long-fiber reinforced fiber composites with thermoplastic plastic matrix, should be reduced or suppressed using suitable process guidance. For this purpose, the radiation energy is to be adapted according to location by researching a process control based on a highly dynamic temperature measurement technique consisting of an infrared camera and a pyrometer integrated in the laser beam path. By using the manufacturing technology to be researched, components can be manufactured faster and thus more cost-effectively compared to the production of fiber composites with a thermoplastic matrix. Due to the use of welding as an alternative to the adhesive process, the use of solvents and adhesives can be avoided. TThe components can therefore be produced more environmentally friendly and without complex surface preparation and can be processed into plastic injection moulding granules after product life. Small and medium-sized companies in plastics processing will thus be able to open up a new market segment, thereby strengthening their competitiveness. On the one hand, jobs can be secured and, on the other hand, created by a technology advantage.

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