Assembly of thermoplastic hybrid carbon composite thermosetting:customization of complex structures – SHORYUKEN
Assembly of thermoplastic hybrid carbon composite thermosetting:customization of complex structures
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Challenges and objectives
Dans l'industrie moderne, l'impression 3D révolutionne la fabrication de composants automobiles, ferroviaires, aéronautiques, ainsi que des prothèses et orthèses. Ce procédé transforme les modèles 3D en objets réels, permettant la production de pièces complexes et sur mesure, sans le coût de moules spécifiques. Il offre une économie de temps et de matériaux, essentielle pour les prototypes et les produits finaux. Néanmoins, l'impression 3D de composites structuraux, notamment ceux renforcés par des fibres, présente des défis, car les pièces produites ont souvent des propriétés mécaniques limitées. L'industrie tend vers l'utilisation de fils renforcés de fibres continues pour surmonter ces limitations, offrant ainsi une meilleure performance mécanique. Ces fils combinent thermoplastiques et fibres de carbone ou de verre, ne fondant pas lors de l'impression et conférant solidité et résistance aux objets fabriqués. Cependant, une limitation majeure demeure : les fibres ne renforcent la pièce que dans une seule direction, ce qui est insuffisant pour les contraintes tridimensionnelles. Le projet SHORYUKEN vise à briser cette barrière technologique en mariant impression 3D et soudage laser. Cette approche innovante permet de créer des composants composites dans différentes orientations, puis de les assembler, offrant une résistance mécanique multidirectionnelle, essentielle pour répondre aux diverses sollicitations des pièces en usage réel.
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The optimization of this innovative design and production process also relies on the development of modeling and simulation tools integrating multi-physics couplings. That is, including information on the interaction between the laser and the material, thermal and mechanical behaviors. Thanks to virtual engineering, it is possible to determine the optimal assembly conditions that ensure superior quality of the welding interface. Ultimately, the process (https://youtu.be/rWZRLFIKUgM?si=J9z2Rj9_J6NOw3OA) and the digital tool developed could convince other industrial sectors such as the railway and automotive industries, for the customization and tailor-made functionalization of parts in small and medium series. For companies in the transport sector, the significant weight reduction of parts designed and manufactured in this way would reduce fuel consumption, and therefore minimize carbon emissions, which are a concern in the current global environmental context. The transition to greener materials also represents a future opportunity. Furthermore, the SHORYUKEN project plans to leverage its findings through the creation of digital educational capsules. These resources would enrich the Master's-level training programs offered by IMT schools, thus contributing to the training of the next generation of engineers.
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Le, A.-D.; Akue Asseko, A.-C.; Cosson, B.; Krawczak, P. Investigating the Effect of Interface Temperature on Molecular Interdiffusion during Laser Transmission Welding of 3D-Printed Composite Parts. Materials. 2023, 16, 18, 6121.
Le, A.-D.; Akue Asseko, A.-C.; Nguyen, T.-H.-X.; Cosson, B. Laser intensity and surface distribution identification at weld interface during laser transmission welding of thermoplastic polymers: A combined numerical inverse method and experimental temperature measurement approach. Polymer Engineering & Science. 2023, 63, 2795–2805.
Le, A.-D.; Cosson, B.; Akue Asseko, A.-C. Investigation of the effect of light scattering on transmitted laser intensity at the weld interface during laser transmission welding of 3D printed thermoplastic parts, International Journal Of Material Forming. 2023, 6, 65.
Akue Asseko, A.-C. Des impressions 3D plus résistantes, Blog I’MTech, 22 Avril 2022. imtech.imt.fr/2022/04/28/des-impressions-3d-plus-resistantes/
Additive manufacturing (or 3D printing) processes has achieved a certain level of industrial maturity. It makes it possible to manufacture parts with complex geometry, personalized in small series, within a reasonable time frame and at a reasonable cost without using specific tooling. However, the additive manufacturing of continuous fiber composite parts remains still limited by the orientation of the fibers in the printing planes. The assembly of 3D printed composite components by laser welding makes it possible, on the other hand, to create functional final 3D parts of large sizes with high mechanical properties (reinforcement fibers in all directions of the space) comparable to those of composite parts which are unfortunately usually limited in shape and geometry, and which are produced by conventional processes requiring expensive tools. Coupling these two processes to produce functionalized and personalized 3D composite parts with very high mechanical performance is unprecedented, and allows the production flexibility and agility with rapid change of product ranges expected by the Industry of the Future. The optimization of this innovative production process implementing a hybridization of technologies will also be based on the development of a simulation tool integrating multi-physics couplings, contributing to the deployment of Industry 4.0. Thus, two types of achievements are expected at the end of the project: a numerical simulation tool of the process, and an optimized functionalized structural part (open source) demonstrator.
Project coordination
ANDRE CHATEAU AKUE ASSEKO (Centre d'Enseignement de Recherche et d'Innovation Matériaux et Procédés)
The author of this summary is the project coordinator, who is responsible for the content of this summary. The ANR declines any responsibility as for its contents.
Partnership
CERI MP Centre d'Enseignement de Recherche et d'Innovation Matériaux et Procédés
Help of the ANR 331,535 euros
Beginning and duration of the scientific project:
January 2022
- 48 Months
