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Simulation of infiltration process of carbon fibres by aluminium alloy in modified GPI method

Hufenbach W. A., Gude M., Czulak A., Bodniewicz D.

Kompozyty

2011

R. 11, nr 4

324-330

The constantly rising demands for lightweight structures, particularly in traffic engineering as well as in machine building and plant engineering, increasingly require the use of continuous fibre-reinforced composite materials. These materials, due to their selectively adaptable characteristic profiles, are clearly superior to conventional monolithic materials. Especially composites with textile reinforcement offer the highest flexibility for the adaptation of the reinforcing structure with regard to complex loading conditions. This paper presents the procedure and evaluation of a gas pressure infiltration process (GPI) for the manufacture of carbon fibre-reinforced aluminium metal matrix composites (CF/Al-MMC). Furthermore, the development of a new furnace for a modified GPI method is presented. In order to verify the new design, numerical simulations of the heating in the furnace chambers were prepared, which finally formed the basis for the improvement of the furnace as well as the GPI process.

Stale rosnące zapotrzebowanie na lekkie konstrukcje, szczególnie w zakresie inżynierii ruchu, a także w budowie maszyn i urządzeń oraz w przemyśle energetycznym, w coraz większym stopniu wymaga stosowania materiałów kompozytowych wzmocnionych włóknem ciągłym. Materiały te, dzięki możliwości selektywnego dopasowania charakterystyk materiałowych, wydają się być lepsze od zwykłych materiałów monolitycznych. Kompozyty wzmacniane materiałami z włókien oferują obecnie najlepszą elastyczność dostosowania struktury wzmocnienia do założonych warunków obciążenia. W niniejszym artykule przedstawiono przebieg oraz ocenę procesu infiltracji gazowej (GPI - ang. Gas Pressure Infiltration), zastosowanego do wytwarzania kompozytów aluminiowych z włóknami węglowymi (CF/Al-MMC). Ponadto zaprezentowano model autorskiego pieca do produkcji zmodyfikowaną metodą GPI. W celu weryfikacji nowej konstrukcji sporządzono numeryczne symulacje nagrzewania w poszczególnych komorach pieca, które w rezultacie pozwoliły na modyfikację pieca oraz procesu.

Development of textile-reinforced carbon fibre aluminium composites manufactured with gas pressure infiltration methods

Hufenbach W., Gude M., Czulak A., Śleziona J., Dolata-Grosz A., Dyzia M.

Journal of Achievements in Materials and Manufacturing Engineering

2009

Vol. 35, nr 2

177-183

Purpose: The aim of his paper is to show potential of textile-reinforced carbon fibre aluminium composite with advantage of the lightweight construction of structural components subjected to thermo-mechanical stress. Design/methodology/approach: The manufacture of specimens of the carbon fibre-reinforced aluminium was realised with the aid of an advanced differential gas pressure infiltration technique, which was developed at ILK, TU Dresden. Findings: The gas pressure infiltration technology enables to fabricate complex carbon aluminium composites with fibre or textile reinforcement using moulds of graphite, but in future development the optimization of infiltration process is required. The load-adapted combination of 3D reinforced semi-finished fibre products (textile preforms) made from carbon fibres (CF) with aluminium light metal alloys (Al) offers a considerable lightweight construction potential, which up to now has not been exploited. Research limitations/implications: Gas pressure infiltration technology enables to fabricate complex carbon aluminium composites with fibre or textile reinforcement using precision moulds of graphite, but in future development the optimization of infiltration process is required. Practical implications: Load-adapted CF/Al-MMC, due to the relatively high stiffness and strength of the metal matrix, allow the introduction of extremely high forces, thereby enabling a much better exploitation of the existing lightweight construction potential of this material in comparison to other composite materials. Originality/value: Constantly rising demands on extremely stressed lightweight structures, particularly in traffic engineering as well as in machine building and plant engineering, increasingly require the use of endless fibre-reinforced composite materials which, due to their selectively adaptable characteristics profiles, are clearly superior to conventional monolithic materials.