Advanced process simulations for thick-section epoxy powder composite structures

James Maguire; Nathan D. Sharp; R. Byron Pipes; Conchúr M. Ó Brádaigh

doi:10.1016/j.compositesa.2022.107073

Advanced process simulations for thick-section epoxy powder composite structures

James Maguire, Nathan D. Sharp, R. Byron Pipes, Conchúr M. Ó Brádaigh

School of Engineering

Research output: Contribution to journal › Article › peer-review

Abstract

Numerical modelling is used to perform process simulations for thick-section composite laminates. Three forms of laminate are used to illustrate how thermal and cure gradients can be reduced by choice of thermal cycle. Low exotherm epoxy powders with the vacuum bag process have shown success in both glass and carbon fiber systems and the results presented in the present work show how the optimum thermal cycle can be determined. The three laminate geometries investigated in the present study included: a one-dimensional flat laminate, a three-dimensional flat laminate, and an axisymmetric section of the cylindrical root of a typical wind turbine blade. Further, energy efficient and cost-effective alternative heating methods are explored.

Original language	English
Article number	107073
Journal	Composites Part A: Applied Science and Manufacturing
Volume	161
Early online date	16 Jul 2022
DOIs	https://doi.org/10.1016/j.compositesa.2022.107073
Publication status	Published - Oct 2022

Keywords / Materials (for Non-textual outputs)

Epoxy powder
Finite element analysis (FEA)
Process simulation
Out of autoclave processing

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10.1016/j.compositesa.2022.107073Licence: Creative Commons: Attribution-NonCommercial-NoDerivatives (CC BY-NC-ND)

Manuscript - FINALAccepted author manuscript, 518 KB

https://www.sciencedirect.com/science/article/pii/S1359835X22002585Licence: Creative Commons: Attribution-NonCommercial-NoDerivatives (CC BY-NC-ND)

Cite this

@article{602d746480414708bbcee13f97cb7782,

title = "Advanced process simulations for thick-section epoxy powder composite structures",

abstract = "Numerical modelling is used to perform process simulations for thick-section composite laminates. Three forms of laminate are used to illustrate how thermal and cure gradients can be reduced by choice of thermal cycle. Low exotherm epoxy powders with the vacuum bag process have shown success in both glass and carbon fiber systems and the results presented in the present work show how the optimum thermal cycle can be determined. The three laminate geometries investigated in the present study included: a one-dimensional flat laminate, a three-dimensional flat laminate, and an axisymmetric section of the cylindrical root of a typical wind turbine blade. Further, energy efficient and cost-effective alternative heating methods are explored.",

keywords = "Epoxy powder, Finite element analysis (FEA), Process simulation, Out of autoclave processing",

author = "James Maguire and Sharp, {Nathan D.} and Pipes, {R. Byron} and {{\'O} Br{\'a}daigh}, {Conch{\'u}r M.}",

note = "Funding Information: The initial stages of this work were carried out at the Composites Manufacturing and Simulation Center at Purdue University, which was funded by the John Moyes Lessells Travel Scholarship from the Royal Society of Edinburgh. The authors acknowledge additional financial support from the Institute of Materials and Processes at the University of Edinburgh and POWDERBLADE, “Commercialisation of Advanced Composite Material Technology: Carbon-Glass Hybrid in Powder Epoxy for Large Wind Turbine Blades”, funded under: European Union Horizon 2020, Fast Track to Innovation Pilot, Grant No. 730747. We also acknowledge the support of industrial partners Suzlon Energy Limited (NL Branch), Johns Manville, and {\'E}ireComposites Teo. Publisher Copyright: {\textcopyright} 2022 The Authors",

year = "2022",

month = oct,

doi = "10.1016/j.compositesa.2022.107073",

language = "English",

volume = "161",

journal = "Composites Part A: Applied Science and Manufacturing",

issn = "1359-835X",

publisher = "Elsevier Science",

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T1 - Advanced process simulations for thick-section epoxy powder composite structures

AU - Maguire, James

AU - Sharp, Nathan D.

AU - Pipes, R. Byron

AU - Ó Brádaigh, Conchúr M.

N1 - Funding Information: The initial stages of this work were carried out at the Composites Manufacturing and Simulation Center at Purdue University, which was funded by the John Moyes Lessells Travel Scholarship from the Royal Society of Edinburgh. The authors acknowledge additional financial support from the Institute of Materials and Processes at the University of Edinburgh and POWDERBLADE, “Commercialisation of Advanced Composite Material Technology: Carbon-Glass Hybrid in Powder Epoxy for Large Wind Turbine Blades”, funded under: European Union Horizon 2020, Fast Track to Innovation Pilot, Grant No. 730747. We also acknowledge the support of industrial partners Suzlon Energy Limited (NL Branch), Johns Manville, and ÉireComposites Teo. Publisher Copyright: © 2022 The Authors

PY - 2022/10

Y1 - 2022/10

N2 - Numerical modelling is used to perform process simulations for thick-section composite laminates. Three forms of laminate are used to illustrate how thermal and cure gradients can be reduced by choice of thermal cycle. Low exotherm epoxy powders with the vacuum bag process have shown success in both glass and carbon fiber systems and the results presented in the present work show how the optimum thermal cycle can be determined. The three laminate geometries investigated in the present study included: a one-dimensional flat laminate, a three-dimensional flat laminate, and an axisymmetric section of the cylindrical root of a typical wind turbine blade. Further, energy efficient and cost-effective alternative heating methods are explored.

AB - Numerical modelling is used to perform process simulations for thick-section composite laminates. Three forms of laminate are used to illustrate how thermal and cure gradients can be reduced by choice of thermal cycle. Low exotherm epoxy powders with the vacuum bag process have shown success in both glass and carbon fiber systems and the results presented in the present work show how the optimum thermal cycle can be determined. The three laminate geometries investigated in the present study included: a one-dimensional flat laminate, a three-dimensional flat laminate, and an axisymmetric section of the cylindrical root of a typical wind turbine blade. Further, energy efficient and cost-effective alternative heating methods are explored.

KW - Epoxy powder

KW - Finite element analysis (FEA)

KW - Process simulation

KW - Out of autoclave processing

U2 - 10.1016/j.compositesa.2022.107073

DO - 10.1016/j.compositesa.2022.107073

M3 - Article

SN - 1359-835X

VL - 161

JO - Composites Part A: Applied Science and Manufacturing

JF - Composites Part A: Applied Science and Manufacturing

M1 - 107073

ER -

Advanced process simulations for thick-section epoxy powder composite structures

Abstract

Keywords / Materials (for Non-textual outputs)

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POWDERBLADE: Commercialisation of Advanced Composite Material Technology: Carbon-Glass Hybrid in PowderEpoxy for Large (60-100m) Wind Turbine Blades

Cite this

Advanced process simulations for thick-section epoxy powder composite structures

Abstract

Keywords / Materials (for Non-textual outputs)

Access to Document

Other files and links

Fingerprint

Projects

POWDERBLADE: Commercialisation of Advanced Composite Material Technology: Carbon-Glass Hybrid in PowderEpoxy for Large (60-100m) Wind Turbine Blades

Cite this