SAMPE Technical Sessions : Accelerating Materials and Process Development Through Digitization
- 11.00-11.20: Advances in Digital Tools for Materials and Process Development by Prof. Anoush Pousartip, University of British Columbia, Director of Research at Convergent Manufacturing Technologies, Canada, SAMPE North America
Composite materials selection and the associated processing, manufacturing and design practice has to date been a complex and often fragile construct that has been primarily driven by the need to manage uncertainty and risk in scale-up. In the last two decades, the packaging of knowledge in the form of predictive simulation supported by characterized materials and standardized workflows has started to change this paradigm, but the best is yet to come. The latest digital approaches, fueled by the explosion in research on Artificial Intelligence (AI) and Machine Learning (ML), are enabling the fusion of physics-based simulation, data from all scales, and the quantification and propagation of uncertainty through all phases of materials and process development, manufacturing scale-up, and in-production control. This creates the potential to take out significant time, risk, and cost from future advanced composite structures development and production. This talk shares examples of the current state-of-the-art while suggesting best practices to benefit from this latest wave of digitalization.
- 11.20-11.40: Fabrication of Large Structures through Friction Screw Extrusion Additive Manufacturing - Status and Challenges by Ton Bor, Technical University of Delft, The Netherlands, SAMPE Europe
Various approaches exist for the additive manufacturing of metallic materials. High-strength aluminium alloys often show metallurgical difficulties when employing fusion-based approaches. Recently, a new solid-state additive manufacturing approach has been developed at the University of Twente that can fabricate aluminium parts providing a fine-scale forged microstructure. The approach is aimed at the fabrication of large-scale builds at high velocities exploiting the relatively high process temperatures developed in the screw-based printhead. The objective is to avoid the use of a full-scale post-deposition heat treatment of the fabricated part but rely on a relatively low-temperature aging treatment only integrating solutionizing and quenching in the fabrication process. Deposition of multiple layers of a medium-strength AA6060 T6 at various build velocities (100 mm/min – 500 mm/min) showed promising mechanical properties obtained in the deposition and build direction in as-printed condition. A subsequently performed aging treatment for 20 hours at 170 °C restored the mechanical properties of the top layers of all builds fabricated at 250 mm/min or faster. Lower layers in the build showed a more limited response due to the influence of the heat of subsequently deposited layers. Approaches to fully restore the mechanical properties across the entire build after the low-temperature aging treatment will be discussed as well the applicability to other medium and high-strength aluminium alloys.
- 11.40-12.00: Study on Epoxy/Nanoparticle Resin and High-Strength, Medium-Modulus Carbon Fiber Reinforced Composite Properties by Dr. Hansong Liu, Senior Engineer, AVIC Composite Technology Center, SAMPE China
This study developed an epoxy resin curing system by introducing a structurally optimized curing agent. Compared to the commonly used DDS curing system, it significantly increased the resin matrix modulus without compromising impact toughness. Rigid nanoparticles were incorporated into two types of epoxy curing systems, resulting in enhanced compressive modulus without decreasing the compressive strength. Microscopic observations revealed uniform dispersion of the nanoparticles within the resin matrix. The addition of rigid particles exhibited only minor effects on the reaction and rheological properties, with minimum viscosity showing a slight increase as particle content rose. Composites were fabricated using the epoxy/nanoparticle resin matrix and high-strength, medium-modulus carbon fiber CCF800H. Compared with composites based on the traditional epoxy/DDS system, the new composites demonstrated a significantly improved longitudinal compressive strength.
- 12.00-12.20: 100% Recycled CF Spun Yarn and Applied Products by Hayato Fukui, Working Group Leader, Toyota, SAMPE Japan
Toyota Industries Corporation is innovatively advancing CFRP recycling through Recycled CF Spun Yarn, utilizing cotton spinning technology to ensure superior fiber orientation and physical properties. This innovative yarn achieves 70% flexural strength and 90% flexural modulus of virgin CF, offering improved usability compared to resin pelletization or nonwoven fabrics. Seamlessly integrating with existing production methods, it supports prepregs, autoclave molding, and resin transfer molding. TICO is also building a comprehensive recycling ecosystem with quality assurance, CAE tools, and external collaboration. Current projects include recycled CFRP heald frames and marine propellers, advancing global cross-industry adoption and demonstrating product reliability.
