TEXTILE PREFORMS FOR COMPOSITE PROCESSING

A State of the Art Report

November 2002

TABLE OF CONTENTS
LIST OF FIGURES.............................................................................................................vii
LIST OF TABLES..............................................................................................................viii
1.0

EXECUTIVE SUMMARY ........................................................................................ 1

2.0

INTRODUCTION....................................................................................................... 3

3.0

THE ROLE OF FIBER ARCHITECTURE........................................................... 5

3.1
3.2
3.3

4.0

Formability........................................................................................................................................... 5
Fluid Permeability............................................................................................................................... 5
Mechanical Properties........................................................................................................................ 6

CLASSIFICATION OF TEXTILE PREFORMING METHODS...................... 9

4.1
Variables for Classification ............................................................................................................... 9
4.2
Fiber Architecture Classification....................................................................................................10
4.3
Fabric Formation Techniques Classification................................................................................11
4.3.1
Linear 1-D Fibrous Assemblies .................................................................................................11
4.3.2
Fabric 2D and 3D Preforms .......................................................................................................11
4.3.3
Planar (2-D) Woven Fabrics ......................................................................................................12
4.4
Fiber Axis and Geometric Dimension Classification...................................................................21
4.5
Direction of Reinforcement Classification ....................................................................................21

5.0

TEXTILE PREFORMING METHODS ............................................................... 25

5.1
Linear Fibrous Assemblies ..............................................................................................................25
5.2
Planar Fibrous Assemblies ..............................................................................................................28
5.2.1
Woven Fabrics ............................................................................................................................28
5.2.2
Nonwoven Fabrics ......................................................................................................................30
5.2.3
Knitted Fabrics............................................................................................................................33
5.2.4
Braided Fabrics...........................................................................................................................35
5.3
Three-Dimensional Fibrous Assemblies........................................................................................38
5.3.1
3-D Woven Fabrics.....................................................................................................................38
5.3.2
Orthogonal 3D Fabrics ...............................................................................................................42
5.3.3
Knitted 3-D Fabrics ....................................................................................................................44
5.3.4
3-D Braided Fabrics....................................................................................................................48
5.3.5
Through Thickness Inserts .........................................................................................................51
5.4
Summary - Selection of Preform Fabrics for Composites..........................................................58

6.0

MANUFACTURING OF COMPOSITE PARTS ................................................ 61

6.1
Formed Shape ....................................................................................................................................61
6.2
Net Shape............................................................................................................................................63
6.2.1
3D Weaving.................................................................................................................................66
6.2.2
3D Braiding.................................................................................................................................67
6.2.3
3D Knitted Composites ..............................................................................................................68
6.3
Textile Preform Composite Applications ......................................................................................68
6.3.1
Preforms for Composite Aircraft Structures .............................................................................68
6.3.2
Preforms for Composites in Automotive Structures ................................................................71

AMPTIAC

7.0

SUMMARY AND CONCLUSIONS ...................................................................... 77

7.1
Preforms Summary...........................................................................................................................77
7.2
Issues Impeding the Use of 3D Textile Preforms..........................................................................80
7.2.1
3D Wovens..................................................................................................................................80
7.2.2
3D Braids.....................................................................................................................................81
7.2.3
3D Knits ......................................................................................................................................82
7.2.4
Through-Thickness Inserts.........................................................................................................82

8.0

REFERENCES .......................................................................................................... 85

vi

TEXTILE PREFORMS FOR COMPOSITE PROCESSING

A State of the Art Report
November 2002

LIST OF FIGURES
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Figure 47
Figure 48
Figure 49
Figure 50
Figure 51
Figure 52

Fabric Techniques: a) Braiding, b) Weaving, and c) Knitting ...................................................... 2

The Role of Preforming in Composites Processing........................................................................ 3
Effect of Fiber Volume Fraction on Permeability for Various Fiber Architectures ..................... 6
Through-the-Thickness Permeability vs. Porosity for Carbon Multiaxial-Warp Knit Preforms. 7
Structural Geometry of Biaxially Woven Fabrics.........................................................................12
Structural Geometry of Triaxially Woven Fabric (Basic Weave)................................................13
Structural Geometry of Triaxially Woven Fabric (Biplane Weave)............................................13
Weft-Knit Constructions.................................................................................................................14
Warp-Knit Constructions................................................................................................................14
Warp-Inserted Weft Knits...............................................................................................................15
Geometry of Two-Dimensional Braid. ..........................................................................................16
Structural Geometry of Triaxial Braid...........................................................................................16
Multi-Layer Triaxially Woven Fabric............................................................................................17
Orthogonal 3D Fabrics....................................................................................................................18
Three-Bar Weft-Insertion Warp Knit.............................................................................................19
LIBA or Hexcel System..................................................................................................................19
Atlantic Researchs Track and Column 3-D Drum Braiding Machine........................................20
Two-Step Braiding..........................................................................................................................20
Cox and Flanagans Preform Classification..................................................................................21
5-D Construction.............................................................................................................................23
3-D Orthogonal Weaves .................................................................................................................23
Idealized Fiber Packings.................................................................................................................26
Geometry of Twisted Yarn.............................................................................................................27
Relationship of Fiber Volume Fraction to Fiber Orientation at Various Twist Level................28
Unit Cell Geometry of Plain Weave ..............................................................................................29
Relationship of Fiber Volume Fraction to Fiber Orientation for Plain Weave...........................30
Schematic of the Novoltex Process................................................................................................31
Unit Cell Geometry of Needle-Punched Nonwoven.....................................................................31
Unit Cell Geometry of Knitted Structure ......................................................................................32
Volume Fraction of Punched Fibers in Relation to Needle Inclination Angle............................33
Relationship of Fiber Volume Fraction to Fiber Orientation for Plain Weft Knit......................34
Braid Formation over Shaped Mandrel..........................................................................................35
Process Window of Fiber Volume Fraction for 2-D Braid. .........................................................37
Setup of a Multiwarp-Weaving Loom...........................................................................................38
Structural Geometry of Various 3-D Woven Fabrics ...................................................................39
Schematic Illustration of Generalized 3-D Woven Fabric Projected to the X-Z Plane..............39
Process Window of Fiber Volume Fraction for 3-D Woven Structures......................................42
Orthogonal 3D Fabric by Direct Method.......................................................................................43
Unit Cell for Orthogonal 3D Fabrics .............................................................................................44
Process Window of Fiber Volume Fraction for Orthogonal 3D Fabrics.....................................44
Multiaxial Warp Knit with Four Layers (0o, 90o, and 45o) of Inserted Yarns...........................45
Unit cell geometry of MWK structure...........................................................................................46
Fiber Volume Fraction vs. s/i ....................................................................................................48
Schematic of a Generalized 3-D Braider .......................................................................................49
Formation of a Rectangular 3-D Track and Column Braid Using 4 Tracks, 8 Columns, and 1x1
Braiding Pattern...............................................................................................................................50
Unit Cell Geometry of 3-D Braid...................................................................................................50
Stitch Formation..............................................................................................................................52
Stitch Seam Pattern .........................................................................................................................53
Stitch Design for a Flat Sample......................................................................................................53
Stitched Flat Panel...........................................................................................................................53
T-Shape Structure Stitched by OSS Technology..........................................................................54
Stitched T-Profiles ..........................................................................................................................54

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AMPTIAC
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
Figure 63
Figure 64
Figure 65
Figure 66
Figure 67
Figure 68
Figure 69
Figure 70
Figure 71
Figure 72
Figure 73
Figure 74

Robotic Stitching System................................................................................................................55

Tailored Fiber Placement (TFP).....................................................................................................56
Tufting Stitches Structure...............................................................................................................57
Reverse Side of Tufted Structure...................................................................................................57
Tufting Head....................................................................................................................................58
Stamping for Automotive Applications.........................................................................................61
Rubber Forming Process.................................................................................................................62
Schematic Drawing of Shear Deformation Mode.........................................................................62
Programmable Powder Preform Process - P4 ..............................................................................63
Alternate Preforming Methods for Composite I-Beams...............................................................64
Braided, Knitted and Stitched Knot Elements for Space Frame Structures................................65
Examples of 3D Woven Preforms..................................................................................................66
Rib-Stiffened Panel (a) and Rocket Nozzle (b).............................................................................67
3D Knitted Sandwich Preform for Bicycle Helmet ......................................................................69
Textile Structural Composites for A Composite Wing.................................................................69
Textile Structural Composites for Helicopter Applications .........................................................70
Application of Textile Composites in Fuselage Structures ..........................................................71
Structural Composites for Passenger Applications.......................................................................72
Structural Composites for STET Rail Vehicle Structures............................................................72
Composite Part Breakdown of Sunrise Body................................................................................73
Net-Shape 2D Knitted Preform for the Front Wheel Wells .........................................................74
Rear and Front Wheel Well Preforms............................................................................................74

LIST OF TABLES
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Table 15

Variables for the Classification of Textile Structural Preforms..................................................... 9

Fiber Architecture for Composites ................................................................................................10
A Comparison of Fabric Formation Techniques...........................................................................11
Type of Reinforcement ...................................................................................................................22
Comparison of Braiding and Filament Winding...........................................................................35
Key Input/Output............................................................................................................................36
Governing Equations ......................................................................................................................36
Advantages and Limitations of Textile-Reinforced Composites.................................................59
Engineering and Processing Parameters for Textile Preforms.....................................................60
Cost and Weight Estimates for Stiffened Panels...........................................................................76
Overview of Textile Structural Composites..................................................................................77
Textile Preform Processes for Composites ...................................................................................78
Engineering and Processing Parameters for Textile Preform Reinforcements...........................79
Issues Impeding the Use of 3D-Woven Composites ....................................................................80
Issues Impeding the Use of 3D Knitted Performs ........................................................................82

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