In the processing of thermoplastic composites, great importance is attributed to the consolidation step, as it can significantly reduce the porosity of the semi-finished product and thus influence considerably the quality of the final component. This work presents an approach to modeling the thermodynamic behavior of composite materials during hot-press consolidation. For this purpose a multi-region, multi-phase and multi-component-mixture model was developed using the simulation toolbox OpenFOAM^®. The sensitivity of the model was tested by varying the thermal parameters and mesh resolution, confirming its robustness. Validity of the model was confirmed by comparing simulation results to experimental data for (i) polycarbonate with 44% carbon fiber by volume and (ii) polypropylene with 45.3% glass fiber by volume. The simulation allows very precise estimation of when a particular temperature, such as the glass transition temperature or melting point, will be reached at the core of a composite. In relation to the total process time, maximum deviation of the simulation from the experimental data amounted to 2.84%. Therefore, the model is well suited for process optimization, it offers a basis for further model implementations and the creation of a digital twin.

The aim of this work was to optimize spot welding of unidirectional tapes made of polycarbonate and carbon fibers. Three studies were performed to investigate the influences of various welding conditions on the quality of the welded spot. First, we used a full factorial experimental design to analyze the influence of temperature and time on the welds’ tensile stress at break. Second, we repeated the experiment with optimized settings and conditions. Finally, we adopted a central composite design (CCD) to investigate the stability of the process. Our results show that temperature had the greatest influence on weld quality. The maximum tensile stress achieved was 23 MPa. Using a relatively high temperature for a short welding time resulted in self-cleaning of the welding head and in a faster and more stable process, and gel permeation chromatography (GPC) confirmed that these conditions caused no additional degradation.

This study investigates the mechanical and dynamic thermomechanical properties of thermoplastic sheet molding compounds (TP‐SMC) combined with thermoplastic polyurethane (TPU) to enhance damping while maintaining structural integrity. The methodology uses SMC, a residual material from UD tape processing, to further enhance sustainability. By combining SMC with TPU, a hybrid material is created that merges the high stiffness of the composite with improved damping capabilities. The research explores the effect of varying TPU content (0%, 20%, 40%, and 60%) on composite properties. Results show that TPU incorporation significantly improves damping properties, with diminishing improvements observed beyond 40% TPU content. The glass transition temperature of the TPU defines the lower application limit of the composites, while lofting behavior, also influenced by the TPU content, defines the upper application limit. These SMC‐TPU composites have potential in automotive and aerospace applications requiring vibration damping and robust performance. Future research should focus on optimizing manufacturing processes and exploring other thermoplastic matrices.

The main aim of this work was to optimize the consolidation of unidirectional fiber-reinforced thermoplastic composite tapes made of polycarbonate and carbon fibers using a heating press and a cooling press in combination. Two comprehensive studies were carried out to investigate the impact of process settings and conditions on the quality of the consolidated parts. The initial screening study provided valuable insights that informed the design of the second study, in which the experimental design was expanded and various modifications, including the implementation of a frame tool, were introduced. The second study demonstrated that the modifications in combination with a high heating press temperature and elevated heating and cooling pressures successfully achieved the desired goals: the desired thickness (2 mm), improved bonding strength (23% increase), and reduced void content (down to 4.64%) in the consolidated parts.

Thermoplastic composites play an increasingly important role in lightweight design. The composite industry employs several production techniques for thermoplast Thermoplastic composites play an increasingly important role in lightweight design. The composite industry employs several production techniques for thermoplast

In the production of thermoplastic composite parts, preheating consolidated laminates is crucial to enhancing formability and bonding during subsequent forming or overmolding in an injection molding machine. However, depending on their initial quality, preheating may cause deconsolidation of the laminate layers. This study evaluated final part quality after reconsolidation, focusing on two primary factors: (i) the consolidation quality before preheating and (ii) the effects of injection molding settings, such as clamping force and mold temperature. Consolidated polycarbonate/carbon fiber plates that differed in their properties were preheated in an infrared oven and then reconsolidated in an injection molding machine. The reconsolidated plates were assessed based on (i) thickness, (ii) warpage, (iii) apparent shear strength and (iv) void content. Our findings indicate that high press temperatures and low press pressures during initial consolidation lead to strong bonding and reduce residual stresses, which minimizes deconsolidation after preheating. Consequently, these reconsolidated plates exhibit levels of quality that are comparable to those achieved after consolidation.