A Model for the Consolidation of Aligned Thermoplastic Powder Impregnated Composites

This paper describes the role of surface energy effects, externally applied pressure, resin flow and fiber bed elasticity on the consolidation of thermoplastic-matrix composites manufactured by the powder impregnation route. Surface energy effects in the spreading of polymer droplets on fiber surfaces are discussed; then a model for the consolidation process is developed, relating the variables mentioned above. Consolidation experiments on powder-impregnated composites of the FIT type (Fibres Impregnees de Thermoplastique) were carried out using a mold attached to a servo-hydraulic testing machine. The model accurately predicts variations in void content during consolidation of carbon fiber/PEEK (CF/PEEK) and carbon fiber/PEI (CF/PEI) laminates. It was found that, at the pressures needed to achieve rapid consolidation, surface energy has a negligible influence on impregnation rate, but its effects on the void topology can be considerable. It was also shown that, when laminates of low void content are required, a minimum pressure is needed to overcome the effect of fiber bed elasticity.