Manufacture of steel–CF/PA6 hybrids in a laser tape placement process: Effect of first-ply placement rate on thermal history and lap shear strength

• Published in: Composites. Part A, Applied science and manufacturing Applied science and manufacturing, 2018-08, Vol.111, p.42-53
• Main Authors: Stokes-Griffin, C.M., Kollmannsberger, A., Ehard, S., Compston, P., Drechsler, K.
• Format: Article
• Language: English
• Subjects: A. Hybrid; A. Polymer-matrix composites (PMCs); C. Finite element analysis (FEA); E. Tape placement
• ISSN: 1359-835X; 1878-5840
• DOI: 10.1016/j.compositesa.2018.05.007

This paper investigates the manufacture of selectively reinforced metal/composite hybrids in a laser-assisted automated tape placement process. Carbon-fibre/PA6 composite tapes were applied to PA6-coated steel substrates. The bonding of the first-ply to the substrate is critical to the success of the hybrid; the effect of first-ply placement rate was investigated for speeds of 25 mm/s, 50 mm/s, 100 mm/s. The interfacial bond strength of the hybrid laminates was determined by ASTM D3165 lap shear tests. A 3D finite element thermal model was formulated to elucidate the thermal behaviour for increasing first-ply placement rate. A method for increasing model efficiency was shown to significantly decrease the computational difficulty while maintaining solution accuracy. Raising the first-ply placement rate from 25 mm/s to 100 mm/s resulted in a fourfold increase in lap shear strength with a maximum value of 22 MPa. The greater strength at higher speeds is attributed to improved synchronisation of the temperature and consolidation pressure history.