Élaboration de pièces composites complexes par consolidation autoclave à partir de préformes textiles thermoplastiques renforcées fibres de carbone

Abstract : Thermoplastic resin composites have been studied for some years by aircraft manufacturer. Current processes studied concerning either prepreg bundle positioning or thermo-stamping of pre-consolidated laminates are not adapted for complex shape as air inlets. To overcome this limitation, this thesis investigates a method based on the manufacturing of fabrics made in commingled/co-woven yarns of carbon and thermoplastic fibres. Then fabrics are consolidated in autoclave. This research project has been divided into two distinct parts. The first part concerns textile shaping study before consolidation. Shear strains of textile preforms have been caracterized by « Bias Extension Test » instrumented with optical device to measure strain field by digital image correlation (2D-DIC ). Textile preform shaping on a double curvature technology test specimen was performed with stamping device. It was also intrumented by cameras to assess shear strain field (3D-DIC). The second part is focused on the study and the optimization of autoclave consolidation conditions and process parameters for thermoplastic composite part manufacturing. Process impacts on composite mechanical properties and microstructure are also studied. Material/process interactions assessment was performed with two CF/PPS semi-pregs : Pipreg ® powdered impregnated fabric from Porcher and TPLF ® commingled fabric with stretch-broken carbon fibers from Schappe Techniques. Results from these two research topics allow to manufacture double curvature composite parts with microstructural properties in accordance with aviation requirements for semi-structural parts. The optimisation of field measurements by 3D-DIC and the semi-preg characterisation in tensile and bending should be developed to improve strain field analysis during fabric shaping. Manufacturing process optimisation by the selection of more efficient materials used for vacumm bagging should also be investigated.
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Julien Patou. Élaboration de pièces composites complexes par consolidation autoclave à partir de préformes textiles thermoplastiques renforcées fibres de carbone. Matériaux. Ecole des Mines d'Albi-Carmaux, 2018. Français. ⟨NNT : 2018EMAC0014⟩. ⟨tel-02178902⟩

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