Investigation of Press Forming Process for CF/PEEK and GF/PP Thermoplastic Composite Materials

Abstract

Aerospace industry requires engineering materials with significant mechanical strength, low cost, easy to recycle, easy to process, and high chemical resistance. Thermoplastic composites are considered as new generation aerospace structural materials due to their superior characteristics. In this study, one of the most common methods used in manufacturing of thermoplastic composite parts from unidirectional (UD) pre-consolidated prepreg (blank), press forming process is investigated and crack behavior of the samples is examined. The forming process is utilized, and consolidated blanks of UD CF/PEEK and GF/PP composite materials are shaped by pressing, and mechanical tests are performed. Micro defects on the samples are monitored by microscopic examination and scanning electron microscopy (SEM) analysis. Results show that when the temperatures of CF/PEEK and GF/PP blank are increased by preheating, the formability of both composites are enhanced. Final outcomes reveal that both CF/PEEK and GF/PP composite materials can easily be used for possible aircraft structures. Additionally, CF/PEEK is found to be appropriate not only secondary structures but also for primary structures.