Dissertations / Theses on the topic 'Hybrid yarn'

In this study, the application of carbon filament yarn (CFY)-based conductive hybrid yarn as the heating element in a textile-reinforced concrete structure is reported. For this purpose, a hybrid yarn having a core-sheath structure (the core is made of carbon filament yarn and the sheath consists of a mixture of short glass and polypropylene fibres) is manufactured by DREF-2000 spinning technique and integrated into textile structure by tailored fibre placement method. Heat can be generated in the concrete structure by passing electric current through the conductive carbon filament yarn core of the hybrid yarn using the principle of resistive heating, where the sheath acts as the protection and isolation layer. From the initial investigations made on a small concrete specimen, important information is gathered and a large concrete slab with integrated conductive hybrid yarn is manufactured. The heat ability and the comfort level of the manufactured concrete slab are measured. The investigations have revealed the potential of using such hybrid yarn for a pointwise heating of the concrete surface for possible appliance in outdoor furniture.

The availability of a considerable amount of waste carbon fiber (CF) and the increased pressure to recycle/reuse materials at the end of their life cycle have put the utilization of recycled CF (rCF) under the spotlight. This article reports the successful manufacturing of hybrid yarns consisting of staple CF cut from virgin CF filament yarn and polyamide 6 fibers of defined lengths (40 and 60 mm). Carding and drawing are performed to prepare slivers with improved fiber orientation and mixing for the manufacturing of hybrid yarns. The slivers are then spun into hybrid yarns on a flyer machine. The investigations reveal the influence of fiber length and mixing ratio on the quality of the card web, slivers and on the strength of the hybrid yarns. The findings based on the results of this research work will help realize value-added products from rCF on an industrial scale in the near future.

With increased use of carbon fibre (CF)-based textile-reinforced thermoplastic composites, the demand of hybrid yarns consisting of carbon filament yarns (CFYs) and thermoplastic filament yarns with improved properties is also high. Hybrid yarn manufacturing using commingling process by means of compressed air shows some distinct advantages over other hybrid yarn manufacturing processes. However, the potential of commingling process for the production of CF-based thermoplastic hybrid yarns is not yet fully explored. In this article, extensive investigations have been carried out for the development of commingled hybrid yarns manufactured from CFY and polyamide 6,6 (PA 6,6) filament yarns with improved adhesion properties between CFY and matrix in composites. Hybrid yarns are manufactured by varying air pressure and keeping overfeeds and delivery speed constant. Moreover, an additional heat treatment on CFY is done online for a better opening of CFY prior to the mixing with PA 6,6 filament yarn. The tensile properties of hybrid yarns as well as different mechanical properties of unidirectional composite, such as tensile, flexural, impact and interlaminar shear strength are investigated. The results show good potential for the development of hybrid yarns produced from CFY and thermoplastic filament yarns with improved adhesion properties for their application in textile-reinforced thermoplastic composites.

This article reports the successful manufacturing of hybrid yarns from virgin staple CF (40 or 60 mm) or recycled staple CF (rCF) by mixing with polyamide 6 (PA 6) fibers of defined length. The hybrid yarns are produced using an optimized process route of carding, drawing, and flyer machine. Furthermore, the influence of CF length, CF type (i.e. virgin or rCF), CF volume content, and twist of the yarn are also investigated regarding the tensile properties of unidirectionally laid (UD) thermoplastic composites. The results show that CF length, yarn twist, and CF content of composites play a big role on the tensile properties of thermoplastic composites. From the comparison of tensile strength of UD composites produced from 40 and 60mm virgin staple CF, it can be seen that the increase of yarn twist decreases the tensile strength. However, the effect of twist on the tensile properties of UD composites manufactured from 40mm virgin staple CF is insignificant. The tensile strength of UD thermoplastic composites manufactured from the hybrid yarn with 40 and 60mm virgin staple CF and rCF is found to be 771 ± 100, 838 ± β1, and 801 ± 53.4 MPa, respectively, in the case of 87 T/m containing 50 volume% CF.

3D textile performs offer a high potential to increase mechanical properties of composites and they can reduce the production steps and costs as well. The variety of woven structures is enormous. The algorithms based on the conventional weaving notation can only represent the possible woven structures in a limited way. Within the scope of this dissertation, a new weaving notation was developed in order to analyze the multilayer woven structures analytically. Technological solutions were developed in order to guarantee a reproducible preform production with commingled hybrid yarns. Terry weaving technique can be utilized to create vertical connections on carrier fabrics, which makes it suitable for the development of complex profiles. A double rapier weaving machine was modified with electronically controlled terry weaving and pneumatic warp yarn pull-back systems. Various spacer fabrics and 3D profiles were developed. A linear take-up system is developed to assure reproducible preform production with a minimum material damage. Integrated cutting and laying mechanisms on the take-up system provides a high level of automation.

Hochduktile Betone (Engl.: Strain-Hardening Cement-based Composites – SHCC) und Textilbetone (engl.: Textile Reinforced Concrete – TRC) sind zwei neuartige Faserbetone, die ein duktiles und dehnungsverfestigendes Zugverhalten aufweisen. SHCC bestehen aus feinkörnigen Zementmatrizen und kurzen Hochleistungspolymerfasern, während TRC eine Kombination aus feinkörnigen Zementmatrizen und kontinuierlichen zwei- oder dreidimensionalen Textilschichten darstellt. Letztere bestehen aus Multifilamentgarnen aus Kohlenstoff, alkalibeständigem Glas oder Polymerfasern. Die hohe elastische Verformbarkeit beider Verbundwerkstoffe bis zum Erreichen der Zugfestigkeit entsteht aus der sukzessiven Bildung multipler feiner Risse. Neben der hervorragenden Risskontrolle und Duktilität weisen diese Verbundwerkstoffe ein hohes Energieabsorptionsvermögen auf, was in Bezug auf kurzzeitdynamische Belastungen eine durchaus erstrebenswerte Eigenschaft darstellt. Obwohl SHCC eine höhere Dehnungskapazität als herkömmliche TRC zeigen, weisen die Textilbetone eine erheblich höhere Zugfestigkeit auf. Darüber hinaus besitzen die textilbewehrten Betone deutlich niedrigere Einflüsse von Anwendungstechnologie und Maßstab auf das Zugverhalten, d. h. eine bessere Robustheit. Daher stellt die Kombination dieser beiden Bewehrungskonzepte einen vielversprechenden Ansatz dar. Während die Kurzfasern für eine bessere Risskontrolle und Erstrissfestigkeit sorgen, sichern die Textilgelege eine hohe Zugfestigkeit sowie Steifigkeit im gerissenen Zustand und eine gleichmäßige Verteilung der Kräfte in der Verstärkungsschicht bzw. im Bauteil. Dieser synergetische Effekt kann jedoch nur durch eine zielgerichtete Materialentwicklung erreicht werden, die eine grundlegende Materialcharakterisierung unter verschiedenen Belastungsszenarien erfordert. Im Rahmen des DFG-finanzierten Graduiertenkollegs GRK 2250 „Impaktsicherheit von Baukonstruktionen durch mineralisch gebundene Komposite“ werden duktile und Impakt resistente Komposite entwickelt, charakterisiert und erprobt, die als dünne Verstärkungsschichten auf bestehende Konstruktionen bzw. Bauelemente aufgetragen werden und dadurch deren Widerstandsfähigkeit und Resilienz gegen extreme kurzzeitdynamische Beanspruchungen signifikant erhöhen. Die in der vorliegenden Arbeit vorgestellten Ergebnisse wurden im Rahmen des A3-Projektes innerhalb des GRK 2250/1 erzielt. Ziel dieser Arbeit war es, die grundlegenden mechanischen Eigenschaften und die Dehnratenabhängigkeit von mineralisch gebundenen Kompositen mit hybrider Faserbewehrung zu erfassen und zu beschreiben. Das Forschungskonzept besteht aus systematischen und parametrischen Untersuchungen der einzelnen Komponenten (Faser, Textil, zementgebundene Matrix), ihres Verbundes und der entsprechenden Verbundwerkstoffe. Hierfür wurden zweckbestimmte Prüfkonfigurationen und dreidimensionale Messverfahren angewandt, die in anderen Projekten des GRK 2250/1 entwickelt wurden. Außer uniaxialen, quasistatischen und dynamischen Zugversuchen wurden quasistatische und dynamische Einzelgarnauszugsversuche durchgeführt. Die wichtigsten untersuchten Materialparameter waren die Art der Kurzfaserbewehrung und der Textilien (Material, geometrische und Oberflächeneigenschaften, Art der Tränkung usw.). Auf Basis der mechanischen Experimente wurde ein analytisches Modell eingesetzt und angepasst, dass das Zugverhalten solcher Komposite in Abhängigkeit von verschiedenen Materialparametern abbilden soll. Zusätzlich zu der detaillierten Beschreibung der Materialeigenschaften, der maßgebenden Mechanismen und synergetischen Effekte bilden die erzielten Ergebnisse eine umfangreiche experimentelle Basis für eine empirische und Modell gestützte Weiterentwicklung und Optimierung dieser Verbundwerkstoffe mit Hinblick auf wirtschaftliche und ökonomische Aspekte.
Strain-hardening cement-based composites (SHCC) and textile-reinforced concrete (TRC) are two novel types of fiber-reinforced cementitious composites that exhibit ductile, strain-hardening tensile behavior. SHCC comprises fine-grained cementitious matrices and short, high-performance polymer fiber, while TRC is a combination of a fine-grained, cementitious matrix and continuous two- or three- dimensional textile layers of multi-filament yarns, usually made of carbon or alkali-resistant glass. Both composites yield high inelastic deformations in a strain-hardening phase due to the successive formation of multiple fine cracks. Such cracking behavior stands for high energy absorption of the composites when exposed to extreme loading, without abrupt loss of load-bearing capacity. In comparative terms, SHCC shows superior strain capacity, while TRC yields considerably higher tensile strength. The addition of short fibers strengthens the matrix by efficiently restraining the micro-cracks’ growth and reducing spallation, while the textile reinforcement ensures a secure confinement of the reinforced concrete element (substrate to be strengthened), as well as a favorable stress distribution. The combination of SHCC and textile reinforcement is expected to deliver high tensile strength and stiffness in the strain-hardening stage along with pronounced multiple cracking. In order to achieve a favorable synergetic effect, a purposeful material design is required based on a clear understanding of the mechanical interactions in the composites. In the framework of the DFG Research Training Group GRK 2250, which aims at enhancing structural impact safety through thin strengthening layers made of high-performance mineral-based composites, this work focuses on developing hybrid fiber-reinforced cementitious materials to be applied on the impact rear side. The development concept builds upon a systematic investigation of various aspects of the mechanical behaviors of SHCC and textile at quasi-static and impact strain rates, including the bond properties of fiber to matrix and textile to matrix. Accordingly, uniaxial quasi-static tension tests were first performed on SHCC, bare textile, and hybrid-reinforced composite specimens. The parameters under investigation were types of short fiber and textile reinforcements, reinforcing the ratio for textile as well as bond properties between textile and the surrounding SHCC. Furthermore, impact tension tests were performed to study the strain rate effect on the synergetic composite response. Finally, single-yarn pull-out tests were carried out under both quasi-static and impact loading rates to supplement the comparative assessment of the hybrid fiber-reinforced composites. These tests yielded shear strength-related parameters for quantifying the bond properties of different materials, which were then used as input of the analytical model developed to describe the mechanics of crack propagation and tension stiffening effect of textile-reinforced composites without short fibers. This model is the first step towards a comprehensive analytical description of the tensile behavior of hybrid fiber-reinforced composites based on the experimental data and input parameters attained through the work at hand.

Der komplexe Verarbeitungsprozess endlosfaserverstärkter Textilthermoplaste beeinflusst maßgeblich die resultierende textile Struktur und damit im gleichen Maße die strukturellen Eigenschaften des Verbundes. Zur vollständigen Ausschöpfung des vielversprechenden Potentials dieser innovativen Werkstoffgruppe ist es daher notwendig, die Fertigungssimulation in den Entwicklungsprozess zu integrieren. In der vorliegenden Arbeit wird eine qualitative als auch quantitative Beschreibung der komplexen Deformationsphänomenologie von Textilthermoplasten beim Thermoformen vorgenommen, wobei die eingehende Analyse der lokalen Textilthermoplaststruktur und -verformung fokussiert wird. Auf Grundlage eines umfangreichen experimentellen Prüfprogramm wird abschließend zur modellbasierten Beschreibung der Deformationsvorgänge ein neuartiges Multi-Skalen-Modell entwickelt, mit dem sich die auftretende Phänomenologie virtuell wiedergeben lässt.

Tese de Mestrado em Arquitectura
A presente Dissertação, intitulada A Presença do Vazio Arquitectónico – Elemento Estruturador de um Edifício Híbrido tem como objectivo o estudo da condição do vazio presente na Arquitectura resultando numa proposta para um objecto híbrido que responde a novas situações de vazio, tirando partido deste último como elemento de composição, estruturação e qualificação espacial. Desta forma, partiu-se da definição do conceito de Vazio, identificaram-se e exploraramse três vazios arquitectónicos, contidos (fechados) e definidos, presentes na cidade tradicional: a praça, o pátio e o saguão. Propõe-se uma reinterpretação dos vazios arquitectónicos acima mencionados, passando por uma proposta de redefinição sem que os mesmos percam a lógica morfológica. presente na memória colectiva do peão comum. Explora-se o seu recurso e aplicabilidade no desenvolvimento de um objecto arquitectónico híbrido, capaz de albergar em si as diversas actividades do dia-a-dia: o habitar, o trabalhar, o aprender e o lazer. Finalmente, a Luz como matéria de caracterização dos espaços desenhados, associada e desenvolvida segundo os vazios propostos.
This dissertation, named The Presence of the Architectural Void – Structural Element of an Hybrid Building is a contemplation about the condition of the element void in Architecture and the development of an Hybrid building based on the idea of the void as a structural and compositional element in the spatial qualification. Starting from the definition of the Void’s Concept, there was the intention of identifying and exploring three types of architectural voids that make part of the traditional city: the square, the courtyard and the patio. I propose a new reading for these architectural voids, pursuing a redefinition without loosing the morphological sense, kept in the common memory of the inhabitant of the city. The overcoming study is tested in an hybrid building that contains the main activities of the daily live: to inhabit, to work, to learn and to play. The light as a material for characterizing space which links and enhances the spatial conditions of the proposed voids.

Textile reinforced concrete (TRC) is an innovative composite material, which is being intensely and practice-oriented investigated on national and international level. In the last few years this material has gained increasing importance in the field of civil engineering. In the context of the collaborative research project SFB 532 at the RWTH Aachen University, research was carried out to understand and to predict the behaviour of different yarn structures in fine grained concrete. Based on the results, innovative commingling yarns were made of alkali-resistant glass fibres and water soluble PVA. These hybrid yarns have an open structure, which improves the penetration of the textile reinforcement by the concrete matrix. Hence, the load bearing capacity of TRC structural elements was significantly improved. This paper presents a technique for the production of such commingling yarns for concrete applications. The mechanical properties of the new yarns are determined due to tensile stress tests. The bond behaviour of the commingling yarns was investigated by pull-out- and tensile stress tests on TRC-specimens. The results of the different tests are being presented and briefly discussed.

La prise de conscience mondiale des enjeux environnementaux a conduit à l’émergence de composites«verts», dans lesquels les fibres naturelles sont amenées à remplacer les fibres synthétiques. Ces nouveaux matériaux offrent des alternatives écologiques aux composites synthétiques traditionnels mais sont difficilement utilisables pour des applications semi-structurales ou structurales. Une solution possible à ce problème est le développement des composites hybrides, en combinant ensemble fibres naturelles et synthétiques. Dans ce cadre, l'objectif de cette étude était de développer des composites hybrides à base de fibres de basalte et de lin. Les composites hybrides ont été élaborés par moulage par infusion sous vide avec une matrice époxy. À des fins de comparaison,des composites 100% à fibres de lin et100%à fibres de basalte ont également été produits. Une caractérisation mécanique quasi-statique et dynamique amontré que l'hybridation permet d’obtenir un composite avec des propriétés mécaniques intermédiaires comparées à celles des composites à fibres de lin ou de basalte. Cependant, l’analyse approfondie des dommages a montré la nécessité d'optimiser la qualité d'adhésion de l'interface fibre/matrice afin d'accroître les performances mécaniques des composites hybrides obtenus. Pour cette raison, différents traitements de modification de surface ont été développés et étudiés pour les fibres de lin et de basalte. Un traitement physique par plasma (Plasma Enhanced Chemical Vapor Deposition) a été appliqué aux fibres de lin et de basalte. Les fibres de lin ont également été soumises à deux traitements chimiques utilisant des espèces enzymatiques et du CO2supercritique. Les effets des traitements sur la stabilité thermique, la morphologie et les propriétés mécaniques des fibres de lin et de basalte ont été étudiés. L’adhérence fibre/matrice a été analysée en réalisant des tests de fragmentation sur des composites monofilamentaires. La qualité de l'adhésion entre les fibres et les matrices époxy et vinylester a été évaluée en termes de longueur critique de fragment, de longueur de décohésion interfaciale et de résistance au cisaillement interfacial. La micto-tomographie haute résolution a été utilisée pour analyser les mécanismes d'endommagement lors des tests de fragmentation. Pour les deux types de fibres, les meilleurs résultat sont été obtenus grâce au traitement par plasma. Ce traitement a consisté à déposer un revêtement homogène de tétravinylsilane à la surface des fibres de basalte et de lin, ce qui a permis une augmentation significative de l’adhérence fibre/matrice, ouvrant ainsi la voie à la prochaine génération de composites hybrides plus respectueux de l’environnement et utilisables pour des applications semi-structurales
Global awareness of environmental issues has resulted in the emergence of “green” composites, in which natural fibres are used to replace synthetic ones. However, in semi-or structural applications, it can be inconvenient to use composites based on natural fibres. A possible solution to this problem is the development of hybrid composite materials, combining together plies of natural and synthetic fibres. In this framework, the aim of this research project was to develop basalt-flax fibre hybrid composites with a view to obtaining more environmentally friendly composites for semi-structural applications. Hybrid composites were produced through vacuum infusion molding with epoxy matrix.For comparison purposes, 100% flax fibre composites and 100% basalt fibre composites were also manufactured. A quasi-static and dynamic mechanical characterization showed that the hybridization allows the production of a composite with intermediate mechanical performances compared to those possessed by flax and basalt composites. However, the damage analysis has revealed the need to optimize the fibre/matrix interface adhesion quality, in order to increase the mechanical properties of the resulting hybrid composites. For this reason, different surface modification treatments have been specifically designed and investigated for flax and basalt fibres. Flax and basalt fibres were treated by the physical process of Plasma Enhanced Chemical Vapor Deposition. Flax fibres were also subjected to two chemical treatments using enzymatic species and supercritical CO2. The effects of the surface modification treatments on the thermal stability, morphology and mechanical properties of flax and basalt fibres have been investigated. The degree and extent of fibre/matrix adhesion were analyzed by micromechanical fragmentation tests on monofilament composites. The adhesion quality between fibres and both epoxy and vinylester matrices has been assessed in terms of critical fragment length, debonding length and interfacial shear strength. High-resolution μ-CT has been used to support the analysis of the damage mechanisms during fragmentation tests. For both flax and basalt fibres, the best results were obtained after the plasma polymer deposition process. This process was able to produce a homogeneous tetravinylsilane coating on the surface of basalt and flax fibres, which resulted in a significant increase in the fibre/matrix adhesion, thus paving the way for the next generation of more environmentally friendly hybrid composites for semi-structural applications

Fibre reinforced composites have higher specific strength and stiffness in comparison to metals. However, composites are susceptible to impact damage resulting in degradation of mechanical properties especially compression strength. Numerous studies have been conducted to improve the impact damage tolerance of composite laminates using modified resin systems, thermoplastic matrices, 3-D fibre architectures and through thickness reinforcement. This work is primarily focussed on incorporating non dissolvable polypropylene fibres (PP) in a thermoset matrix for improving the damage tolerance. Commingling and wrapping techniques have been investigated. PP fibres have been incorporated at the preform stage and hence do not adversely affect the viscosity of the resin during infusion. The healing effect of PP fibres on impact damaged composite laminates when heating is introduced has also been studied. High velocity impact test results showed that using commingled glass/PP fibres increased the total energy absorption of composite laminates by 20% due to the extensive plastic deformation of the PP fibres and through the use of toughening mechanisms in the form of resin cracking and delamination. It has been found that PP fibres provide protection to the glass fibres during low velocity impact loading, so fewer fibre breakages occur which lead to improved residual properties compared with pristine glass laminates. Compression after impact (CAI) tests showed that the residual strength as a percentage of non-impacted strength increased with percentage of PP fibres used. For impact of 20-50J, glass/epoxy laminates retained 32 45% of their compressive strength while laminates with 7%, 13% and 18% PP fibres retained 37 50%, 42-52% and 43-60% of their compressive strength, respectively. It was also observed that glass/PP woven laminates had better compressive strength retention (62 83%) than the glass/PP non-crimp laminates (37-50%). Composite laminates with high-modulus PP fibres (Innegra) exhibited higher residual compression strengths in comparison to laminates with lower modulus PP fibres. For 15-50J impact, glass/Innegra laminates showed residual compression strength of 50 63% in comparison to 39-60%; laminates without thermoplastic fibres exhibited 33 43% residual compression strength. Modulus of thermoplastic fibres appears to be important at higher energy levels. Healing of damaged commingled laminates produced a significant reduction in the damage area and a corresponding increase in CAI strength after heating at 200ºC; CAI strength of healed laminates is about 85% of undamaged samples in comparison to 60% for non-healed samples. A novel micro-wrapping technique, developed in this work, demonstrated significant reduction in damage area (46%) in comparison to the commingling method. Core wrapped laminates had higher residual strength (43-60%) than glass laminates (33-43%). Better PP distribution in core-wrapped composites helped to decrease the PP rich areas and the impact damage did not propagate easily in comparison to commingled composites. However due to the reduction in damage area, impact energy absorption in core wrapped laminates was lower than for commingled.

碩士
逢甲大學
紡織工程所
91
The woven type geogrids are manufactured more nowadays in Taiwan and it is short of research data and requires investigating deeply. We designed and produced a geogrids processer in this thesis. We spun the hybrid core yarn with the Twist-Warp Machine and weaved geogrids with the hybrid core yarn. The improvement and fabrication with geogrids processer was center on shedding mechanism, picking mechanism, beating mechanism, let-off mechanism, and tack-up mechanism. The results showed that the geogrids processer could manufacture geogrids successfully. The geogrids request high strength and low elongation. In this thesis, we spun hybrid core yarn with two bundles of high tenacity PET (2000 D/384 f, core) and one bundle of PP (1000 D/120 f, sheath) with the Twist-Warp Machine. The results showed that we could spin PP/high tenacity PET hybrid core yarn with twist factor down to 8.3. The strength is 323.7 N and the elongation is 13.2 % with the PP/high tenacity PET hybrid core yarn. Weaved the geogrids with the PP/ high tenacity PET hybrid core yarn that provided with high strength, low elongation and lightweight. In this thesis, the manufacture conditions, mechanical properties, acid-resisting property, base-resisting property and light and water exposure-resisting property on geogrids weaved with PP/high tenacity PET hybrid core yarn was investigated. The results showed that we could obtain the best mechanical properties with geogrids when the heating temperature was 190 ℃, heating time was 4 minutes. The longitudinal strength was 46.4 kN/m, the transverse strength was 23.6 kN/m, the junction strength was 6.2 kN/m, and the longitudinal elongation was 11.4 % of the geogrids. The strength of the geogrids didn’t reduce with the acid-resisting and base-resisting tests. The strength reduced clearly with the light and water exposure-resisting (600 hours) test.

Gegenstand der vorliegenden Dissertationsschrift ist die Entwicklung und Umsetzung von neuartigen Hybridgarnen aus recycelten Carbonfasern (rCF) und Polyamid (PA) 6-Fasern für thermoplastische Verbundbauteile mit hohem Leistungsvermögen. Diese Hybridgarne können die hervorragenden mechanischen Eigenschaften der rCF im Gegensatz zu bisherigen Lösungen auf Basis von Spritzguss und Vliesstoffen in hohem Maße ausnutzen. Bedingt durch deren spezielle Fasereigenschaften (insbesondere hohe Querkraftempfindlichkeit, Sprödigkeit und fehlende Kräuselung) wurde dafür die Prozesskette der konventionellen Stapelfasergarnherstellung, bestehend aus Krempel, Strecke und Flyer, umfangreich analysiert und technologisch-konstruktiv weiterentwickelt, wodurch erstmalig eine schonende und gleichmäßige Herstellung der Hybridgarne ermöglicht werden konnte. Für eine reproduzierbare und effiziente Prüfung der Faserlänge der rCF wurde zudem ein anforderungsgerechtes Faserlängenmesssystem auf Basis der Fibrographmethode entwickelt. Die im Rahmen der Arbeit abschließend durchgeführten Verbund-prüfungen belegen das enorm hohe Potential der Hybridgarne, die über 80 % der Verbundzugfestigkeit von vergleichbaren Referenzprüfkörpern aus Carbon-Filamentgarn und PA 6-Matrix erreichen. Das entwickelte analytische Modell bietet zudem die Möglichkeit zur Berechnung der Verbundzugkennwerte in Abhängigkeit wesentlicher Faser- und Hybridgarnparameter.

Die Textiltechnik ermöglicht den Einsatz von rezyklierten Kohlenstofffasern in thermoplastischen Faserverbundwerkstoffen mit hohen Festigkeitsanforderungen. Das Erreichen vergleichbarer mechanischer Eigenschaften entsprechender endlosfaserverstärkter Verbundwerkstoffe wird durch die Nutzung von Stapelfaser-Hybridgarntextilien realisiert. Die Anwendung von thermoplastischen Hybridgarntextilien für die Herstellung von mehr als 100.000 Bauteilen pro Jahr erfordert jedoch eine kurze Taktzeit zur Imprägnierung und Konsolidierung des textilen Halbzeugs. Diese ist in dem derzeitigen Stand der Technik nicht gegeben, sodass hier Forschungsbedarf besteht. Die vorliegende Arbeit präsentiert eine Methode zur Reduktion der Taktzeit zur Imprägnierung und Konsolidierung komplexer Bauteilgeometrien auf Basis leitfähiger Hybridgarntextilien von derzeitig mehreren Minuten auf unter eine Minute, mit Potenzial zur weiteren Minimierung. Dies erfolgt mittels In-situ-Erwärmung im formgebenden Werkzeug unter Nutzung der Widerstandsverluste bei Stromfluss durch die leitfähigen Verstärkungsfasern. Neben der Charakterisierung und Simulation der Erwärmung im Mehrlagengewebe wird eine Parameteranalyse an generischen Probekörpern durchgeführt, um die Machbarkeit zu demonstrieren. Genauso findet eine erfolgreiche Skalierung der Technologie durch Übertragung der Ergebnisse auf eine komplexe Bauteilgeometrie anhand einer innovativen Werkzeugtechnologie statt. Am Ende der Arbeit erfolgt eine wirtschaftliche Betrachtung der kompletten Prozesskette von der einzelnen Faser, über den Hybridroving und das Mehrlagengewebe, bis zum fertigen Bauteil. Die Arbeit zeigt eine Technologie zur wirtschaftlichen Fertigung von Bauteilen aus rezyklierten Kohlenstofffasern in unter einer Minute Taktzeit. Des Weiteren bieten sich Vorteile durch die geringen Materialkosten des Hybridrovings, den hohen Grad der Automatisierung und die energetisch effiziente intrinsische Erwärmung des Halbzeugs.

Der komplexe Verarbeitungsprozess endlosfaserverstärkter Textilthermoplaste beeinflusst maßgeblich die resultierende textile Struktur und damit im gleichen Maße die strukturellen Eigenschaften des Verbundes. Zur vollständigen Ausschöpfung des vielversprechenden Potentials dieser innovativen Werkstoffgruppe ist es daher notwendig, die Fertigungssimulation in den Entwicklungsprozess zu integrieren. In der vorliegenden Arbeit wird eine qualitative als auch quantitative Beschreibung der komplexen Deformationsphänomenologie von Textilthermoplasten beim Thermoformen vorgenommen, wobei die eingehende Analyse der lokalen Textilthermoplaststruktur und -verformung fokussiert wird. Auf Grundlage eines umfangreichen experimentellen Prüfprogramm wird abschließend zur modellbasierten Beschreibung der Deformationsvorgänge ein neuartiges Multi-Skalen-Modell entwickelt, mit dem sich die auftretende Phänomenologie virtuell wiedergeben lässt.