COMPOSITES SCIENCE AND ENGINEERING

Preparation of carbon fiber composite honeycomb structures and mechanical behavior of axial crush

ZHU Hongwei, LIU Ke, ZHAO Changfang

2024, 0(12): 5-11. DOI: 10.19936/j.cnki.2096-8000.20241228.001

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Carbon fiber reinforced composites (CFRP) have excellent mechanical properties, especially cushioning energy absorption properties. The structure type of the composite material products has a great influence on the mechanical properties, and a reasonable structural shape can better utilize the energy absorption and specific energy absorption potential of the composite material. The hexagonal column honeycomb structure of honey bees has been naturally selected to have good load-bearing stability. Bionic honeycomb structure, the periodic hexagonal cylinder honeycomb structure was prepared by assembling and bonding the single plates together, in which the single plate was obtained by vacuum hot-pressing method using T700 prepreg through a combination mold. The quasi-static impact experiments of the single plate were carried out by universal electronic material testing machine, and the progressive failure and delamination damage mechanisms were analyzed. To better simulate the impact failure behavior of the composite honeycomb structure, a damage mechanism that simultaneously considers both the intralaminar and interlaminar damage mechanisms of the CFRP laminate was proposed based on the continuum medium damage mechanics, and the incremental constitutive model in finite element form was developed, whose prediction results match well with the experimental results and verifies the feasibility of the finite element method. On this basis, simulations of the honeycomb structure were carried out to discuss the impact response of the honeycomb structure and analyze the failure modes and energy absorption effects under impact loading. The results of this paper demonstrate the stability and energy absorption characteristics of the honeycomb structure, which provides a reference for the design and application of CFRP structures in cushioning energy absorption engineering.

Effect of EMAA stitching pattern on impact resistance of composites

YIN Zhihao, GE Chaokun, XU Ping, TIE Ying, ZHANG Zhenzhen, JU Guang

2024, 0(12): 12-18. DOI: 10.19936/j.cnki.2096-8000.20241228.002

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In aerospace, stitched composites are widely used due to their excellent impact resistance. Different stitch patterns affect the impact resistance of composites, and during the stitching process, the stitches also have an effect on the intra-laminar properties of composites. In this paper, a combination of multi-scale modeling and experimental methods is used in order to investigate the effects of EMAA stitch spacing and stitch direction on the impact resistance and intra-laminar properties of composites. The results show that the validity of the multiscale modeling of stitched composite panels is verified. Stitching led to a decrease in the in-face properties of the composite laminates around the stitches, but improved the impact resistance in the out-face direction. Comparison of different stitch spacings showed that the smaller the stitch spacing, the higher the improvement in the impact resistance of the composite. Comparison of the performance of the two different stitch orientations, 45° and 0°, showed that the 45° stitch orientation was superior to the 0° stitch orientation in terms of both in-plane and out-of-plane performance.

Study on tensile and compression failure behavior of ultra-thin-ply carbon fiber reinforced composite panel

LIU Yanpeng, HAN Yuze, REN Zhongjie, REN Mingfa

2024, 0(12): 19-25. DOI: 10.19936/j.cnki.2096-8000.20241228.003

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The thinning of carbon fiber reinforced composites has further improved their mechanical properties and design space. In order to investigate the basic mechanical properties and failure mechanism of ultra-thin-ply carbon fiber reinforced composites, unidirectional composites with four ply thicknesses of 24 μm, 55 μm, 75 μm and 100 μm were prepared and subjected to longitudinal tensile, transverse tensile, longitudinal compressive, and transverse compressive experiments. Analysis was conducted on the influence of ply thickness on the modulus and strength of carbon fiber reinforced composites, revealing the failure modes and mechanisms of unidirectional carbon fiber reinforced composites with different ply thicknesses. The results indicate that the influence of ply thickness on the longitudinal tensile strength, transverse tensile strength, longitudinal compressive modulus and transverse compressive modulus of carbon fiber reinforced composites is not monotonic. Proper ply thickness can enable the composite to exhibit the best mechanical properties. Furthermore, the thickness of the ply also has a significant impact on the failure mode of the unidirectional carbon fiber reinforced composites, mainly manifested in the degree of transverse splitting, fiber fracture, delamination, and crack initiation and propagation mode.

UV aging properties of five types of plant fibers/polyethylene wood plastic composites

HUANG Miaolin, FANG Hai, HUO Ruili, CHEN Hang

2024, 0(12): 26-33. DOI: 10.19936/j.cnki.2096-8000.20241228.004

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In order to investigate the UV aging properties of polyethylene (PE) based wood plastic composites, five types of plant fibers (poplar, rice husk, bamboo, rice straw and straw fibers) were incorporated into PE. The 120-day artificially accelerated UV aging test was carried on to analysis the color stability, quality, mechanical properties, and microstructure of five types of plant/PE composites before and after aging. The results indicate that artificial UV aging causes stable color difference changes, a decreased quality (during the first 30 days) followed by an increase, and poorer mechanical properties, with cracks and warping in the sections in the five PE-based wood plastic composites. After the 120 days of UV aging, the reductions of the flexural and tensile strength of poplar/PE composites are 32.04% and 16.31%, respectively; for the rice husk/PE composites, the reductions are 34.95% and 26.41%, respectively; for the rice bamboo/PE composites, the reductions are 27.57% and 21.85%, respectively; for the rice straw/PE composites, the reductions are 33.06% and 27.85%, respectively; and for the straw/PE composites, the reductions are 25.57% and 23.95%, respectively.

Remodelable phenolic resin and its composites based on dynamic boronic ester bonds

XING Xiaolong, HUANG Jinxin, ZHANG Jian, LIU Yi, RUAN Yingbo, ZHANG Chengshuang

2024, 0(12): 34-42. DOI: 10.19936/j.cnki.2096-8000.20241228.005

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A novel boron-containing phenolic resin (BNR) with a phenylboronic acid structure as side groups was successfully synthesized using a hydrothermal method to address the issue of none remouldability in traditional phenolic resin-based composites. The BNR resin demonstrated a high yield of 94.1% and could be efficiently prepared. Upon heating at 160 ℃, the BNR resin underwent curing without any curing agents, forming a boronic ester cross-linked phenolic resin with reshaping ability. The cured resin exhibited remarkable thermal stability, with a carbon yield of 66%, making it suitable as a flame-retardant composite matrix. Furthermore, compared to traditional phenolic resins, the phenolic resin with boronic ester cross-linkages displayed complete stress relaxation under heat and imparted excellent remouldability to the composites. These findings highlight the potential of the BNR resin as a promising candidate for the development of advanced and versatile ablative composites.

Preparation and properties of TDE-85 resin system strengthened and toughened by biphenyl epoxy resin

HOU Zhenhong, LU Qi, ZHAO Xingnuo, XU Jinwen, XIA Hongwei, ZHANG Song, HOU Ruigang, ZHOU Quan

2024, 0(12): 43-48. DOI: 10.19936/j.cnki.2096-8000.20241228.006

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Epoxy resin is widely used in coatings, electronic packaging materials and adhesives because of its strong adhesive strength and good thermal stability, but its high cross-linking density also brings the problem of brittleness and poor toughness, which has become the main factor restricting its development and application. A high performance epoxy resin (TDE-85) was modified by biphenyl epoxy resin 3,3′,5,5′ -tetramethylbiphenyl bisphenol diglycidyl ether (TMBP) with 3,3′ -diaminodiphenyl sulfone (3,3′-DDS) as curing agent by melt blending method. The mechanical properties of the modified resin system were studied. The results of polarizing microscope and SEM showed that the liquid crystal structure could be well dispersed in the epoxy resin matrix and strengthened and toughened. The results show that when the TMBP content is 6wt%, the mechanical properties of the cured material are obviously improved, the impact strength and flexural strength are increased by 30% and 27% respectively, and the strength and toughness is obviously improved. When the TMBP content is 4wt%, the tensile strength and tensile modulus reach the maximum of 93.69 MPa and 5.39 GPa.

Preparation and properties of bisphenol M cyanate ester resin for hot melt prepreg

YAO Zhuojun, HAO Shang, LI Qianfu, YANG Zhengqiang, ZHANG Yanda, LIU Qianli

2024, 0(12): 49-53. DOI: 10.19936/j.cnki.2096-8000.20241228.007

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In this paper, CM01 resin for hot melt prepreg was prepared by using bisphenol M cyanate ester resin as raw material, and employing the method of cyanate ester monomer pre-polymerization which is then catalysted by copper acetylacetonate and nonylphenol. The processability of the resin and the dielectric, hygroscopic, thermomechanical and mechanical properties of the cured resin were investigated. The properties of CM01 resin were compared with the ones of CA01 resin which was prepared by bisphenol A cyanate under the same conditions. The results show that CM01 resin has good processing fluidity, which is suitable for hot melt prepreg preparation. Prepregs prepared by CM01 resin have a wide window for high temperature pressing, thus suitable for composite molding. The cured CM01 resin has excellent dielectric and hygroscopic properties. The dielectric constant and dielectric dissipation factor of cured CM01 resin are 2.78~2.80 and 0.004 53~0.005 11 respectively in the frequency range of 7~15 GHz, while those of cured CA01 resin are 2.99~3.01 and 0.010 8~0.012 3 respectively. The saturated water absorption of cured CM01 resin is 0.85%, which is 60% lower than that of cured CA01 resin. The cured CM01 resin has good heat resistance and mechanical properties, the glass transition temperature T_g is 198.1 ℃, the tensile strength and tensile modulus are 66.51 MPa and 3.06 GPa respectively, the elongation at break is 2.39%, the flexural strength and flexural modulus are 134.45 MPa and 3.09 GPa respectively.

Vibration band gap characterization of four-ligament chiral sandwich structures

ZHANG Jinguang, CHEN Rui, DOU Yukuan, LU Jikun, WEN Xianglong

2024, 0(12): 54-61. DOI: 10.19936/j.cnki.2096-8000.20241228.008

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In this paper, to attenuate the elastic wave, a new type of sandwich structure with a four-ligament chiral structure as the core and carbon fiber composite material as the panel is proposed. Firstly, based on Bloch’s theorem and COMSOL finite element software, the vibration bandgap of the four-ligament chiral structure is solved; secondly, the influence of the filling materials of the nodes of the protocell and the geometrical parameters on the vibration bandgap of the chiral structure are analyzed; thirdly, the transmission characteristics of the waves within the four-ligament chiral sandwich structure are investigated in the frequency domain; and lastly, the experiments on the vibration transmission and attenuation characteristics of the four-ligament chiral sandwich structure are carried out. The study shows that: the chiral structure node filling material can produce a low-frequency bandgap, and the geometric parameters have a great influence on the bandgap, by adjusting the geometric parameters, the bandgap can be made to be in the low-frequency region; when the vibration frequency is in the range of the bandgap, the chiral structure has a good attenuation characteristic. These findings will guide the application of four-ligament chiral sandwich structures in engineering.

Lager optimization design of CFRP battery-pack enclosure using entropy-based TOPSIS approach

SU Hailiang, MA Lianhua, ZHAN Xin, QIN Jirong, ZHANG Yanhui

2024, 0(12): 62-68. DOI: 10.19936/j.cnki.2096-8000.20241228.009

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In order to achieve lightweight design for a new energy vehicle battery box, a lightweight and high-strength carbon fiber reinforced plastic (CFRP) was used to replace the structural material. The entropy-based TOPSIS method based on orthogonal test table was utilized for multi-objective layup optimization design. The mechanical properties of CFRP laminates were predicted using the Digimat commercial software, and their correctness was verified through mechanical performance tests. Based on laminate design criteria and equal stiffness design principles, the preliminary structural plan for the CFRP battery box was determined. Finally, the laminate layering was optimized with the goal of minimizing deformation and maximizing the first-order mode, resulting in the best performance CFRP battery box structure. The research findings indicate that the optimized CFRP battery box shell is 46.74% lighter than the original metal structure, and the overall performance of the battery box structure is also improved.

Prediction of the ultimate loads and structural optimization design for the wind turbine blades with glass-carbon laminate based on neural network

XU Quanwei, GUO Xiaofeng, QIAO Shujie, LI Siqing, CHE Jiangning

2024, 0(12): 69-74. DOI: 10.19936/j.cnki.2096-8000.20241228.010

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In order to optimize the layup structure of wind turbine blades with the practical ultimate loads, the study was conducted on the DTU10MW wind turbine blade with a length of 89 m. A neural network model was developed through a Latin hypercube experiment, by using the root triaxial ply thickness, trailing edge uniaxial ply thickness, spar cap uniaxial ply thickness, pre-bend value of blade-tip, pre-bend index as input variables, and the blade tip deformation and ultimate loads of blade root as output variables. The layup structure of the wind turbine blades was optimized by using the particle swarm algorithm. For the optimized design of the glass-carbon hybrid blades, a newly proposed method for calculating blade mass and cost was used to analyze their load characteristics and economic feasibility. This research provides practical reference value for the optimization design and cost evaluation analysis of large-scale wind turbine blades with glass-carbon hybrid structures, and holds significant importance for the lightweight design of wind turbine units.

Research of the influence of milled carbon fiber pollution on lightning protection of wind turbine blades

XU Jun, CUI Xiaopeng, WANG Xiangdong, LI Chengliang, HUANG Huixiu

2024, 0(12): 75-79. DOI: 10.19936/j.cnki.2096-8000.20241228.011

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In order to analyze the influence of milled carbon fiber pollution on lightning protection of GFRP, simulation analysis of electrostatic field based on FEM was established. Furthermore, high volt lightning tests were implemented with GFRP sample (0.5wt% milled carbon fiber). The results showed that the GFRP skin/PVC core material area and the pure skin area did not undergo breakdown in the high volt lightning tests. In the experiment, multipleting flashovers of milled carbon fibers were observed at the shallow surface of the fiberglass. The comparative analysis between numerical simulation and experimental results shows that the phenomenon is consistent with the conclusion in the simulation results that induced flashover may occur when the milled carbon fiber depth is less than 0.3 mm, and cannot occur at greater depths.

Experimental study on electrical heating stracture of composite based on laser-induced graphene

ZHANG Dichao, YAN Gang, YU Xinfei

2024, 0(12): 80-86. DOI: 10.19936/j.cnki.2096-8000.20241228.012

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In order to meet the requirement of anti/deicing for aircrafts flying at high altitude, a method of fabricating composite structure with electrical heating function with laser-induced graphene technology is proposed in this paper. Based on the icing characteristics of the leading edge of the wing, a wavy pattern with dense heating lines in the middle and sparse heating lines in the sides is designed. Utilizing the advantages of laser-induced graphene technology, i.e., fast, high efficiency and low cost, the graphene heating line pattern is induced on the surface of polyimide paper by carbon dioxide laser, and then is co-cured with composite prepregs to form a laminated structure. A series of electrical heating tests are carried out to analyze the temperature distribution rules along the vertical and horizontal directions on the surface of the structure and melting situation for ices with certain thickness and mass, under certain currents applied. The results have demonstrated the feasibility and effectiveness of the proposed and fabricated composite structure with electrical heating function.

Research on the confinement effect of fiber-reinforced polymer materials reinforced concrete

QIAN Yinmin, SHEN Hanfeng, WANG Tao, ZHANG Kaijin

2024, 0(12): 87-95. DOI: 10.19936/j.cnki.2096-8000.20241228.013

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To accurately predict the confinement effect of fiber-reinforced composite materials applied to concrete, strength and strain effect models for fiber-reinforced composite-constrained concrete were proposed based on Random Forest and CatBoost algorithms. Data of 502 concrete specimens with fiber-reinforced composite wrapping along the lateral side were collected, including parameters such as concrete cross-sectional dimensions, fiber-reinforced composite wrapping thickness, fracture strain and elastic modulus, unconstrained concrete strength and strain, constrained strength effect, and constrained strain effect. Existing empirical models for confinement strength and strain effects were compared and evaluated. Three evaluation metrics, namely determination coefficient (R²), root mean square error, and mean absolute error, were selected for the comparative evaluation of the developed Random Forest and CatBoost models. The results showed that for the confinement strength effect, the R² values of the Random Forest model and CatBoost model were generally above 0.84, higher than the existing empirical models (0.78 to 0.83). Regarding the confinement strain effect, the R² values of the Random Forest model and CatBoost model were generally above 0.87, also higher than the existing empirical models (0.65 to 0.75). This indicated that the performance of the developed Random Forest and CatBoost models was superior to the existing empirical models, and both models could provide relatively accurate predictions of the confinement effect of fiber-reinforced composite materials applied to concrete. Particularly, the CatBoost model demonstrated higher accuracy.

Design and verification of repair process for wind turbine blade with penetrating damage

XING Hairui

2024, 0(12): 96-105. DOI: 10.19936/j.cnki.2096-8000.20241228.014

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In order to study the repair process of wind turbine blade composite material shell with penetrating damage, a 50 m level blade was selected with artificial damage to its shell and a repair process method was designed. The repaired blades were subjected to full-scale fatigue tests and post fatigue static tests to verify the reliability of the repair process, and the impact of the repair on the blade structure was evaluated. The results indicate that for blade shells with extensive penetrating damage, it is necessary to make lining plates on the corresponding blade production molds as the repair basis to ensure that the repaired surface of the blade shell remains consistent with that before the damage; in cases where manual repair is not feasible due to limited space, the repair method of opening a window can be used; the repaired blades were subjected to fatigue tests and post fatigue static tests to verify the reliability of the repair process. The experimental results indicate that the repaired blade structure has little impact.

Experimental study on compressive properties after high velocity impact of composite laminates

XUAN Shanyong, WANG Xiaopei, WANG Zhiyuan, ZHANG Nan, FU Bin, FAN Xin

2024, 0(12): 106-112. DOI: 10.19936/j.cnki.2096-8000.20241228.015

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In this paper, the compressive behavior, failure mode and failure mechanism of composite laminates after high velocity impact were studied by compressive tests. The experimental results show that the failure load and the failure mechanism of laminates impacted at different positions are different. The failure mode of laminates impacted at center position is mainly layered buckling failure, while the failure mode of laminates impacted at quarter position is compression and overall buckling failure. The compressive failure load of laminates impacted by high velocity is reduced by the increase of the damage area. As the impact velocity increases, the compressive failure load decreases and then increases. The failure load is minimized when the impact velocity is slightly higher than the ballistic limit. The residual compressive properties of laminates impacted at quarter position is worse than the center position.

Development of composite material calibration system for nuclear magnetic resonance logging tool

NAN Wujiang, YU Cheng, WANG Liangyou

2024, 0(12): 113-118. DOI: 10.19936/j.cnki.2096-8000.20241228.016

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The composite material calibration system of nuclear magnetic resonance logging tool is to calibrate the porosity by placing the probe in a water jacket and collecting the pore fluid signals of the formation. The overall structure, cylinder, cylinder support, copper foil shielding system, and circulation system of the composite material calibration system have been optimized and designed in this article. Through finite element analysis calculations and optimization of the production process, the stiffness of the entire calibration system and the reliability of the connections have been improved without increasing the total weight of the calibration system. This optimization has made the overall structure of the product more rational and convenient to operate. The composite material calibration system successfully completes the instrument calibration tasks and serves as an experimental platform for research in nuclear magnetic resonance logging technology.

Curing deformation prediction of L-shaped composite stringer based on machine learning

SUN Xiaohui, LÜ Yi, WANG Jianjun, ZHANG Xianzhi, XIE Jiaqing

2024, 0(12): 119-125. DOI: 10.19936/j.cnki.2096-8000.20241228.017

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Aiming at the problem that the curing deformation mechanism of composite structure in the process of manufacturing is very complicated, and many parameters are involved and constantly change during the curing process, a method based on machine learning was proposed to predict the curing deformation of L-shaped composite stringer in the molding process. ABAQUS finite element software was used to simulate the curing molding process of L-shaped composite stringer in autoclave, and a data set of curing spring-in angle of L-shaped composite stringer was established, which was characterized by six parameters of the curing process temperature curve: two-stage heating rate, two-stage holding temperature and two-stage holding time. Then RBF neural network was constructed and curing deformation prediction was carried out. The results show that this method has high prediction accuracy and efficiency, the prediction error is less than 3%, and the model time is only 1.25 s.

Compression failure mechanism and progressive damage analysis of 3D woven composites

GUO Xiumei, WANG Kun, ZHANG Nan, LI Chao, ZHOU Guangming

2024, 0(12): 126-133. DOI: 10.19936/j.cnki.2096-8000.20241228.018

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A combination of experiment and simulation was used to study the progressive damage and failure modes of 3D woven composites. The stress-strain curves of the material were obtained through the warp and weft compression test. Based on the microscopic characterization of the material, the microscopic finite element cell model was established to simulate the stress-strain response and damage mechanism. Through the comparison of simulation and experiment, it is considered that the simulation results agree well with the test results. The compressive modulus and strength of the material along the weft are higher than those along the warp. Under the weft compressive load, the main reasons for the failure of the 3D woven composite material are the crushing fracture of weft yarns and the cracking of the matrix. Under warp compressive load, warp yarns are curved yarns, which extrude the matrix and weft yarns, which easily lead to the crushing of the matrix between the yarns and produces delamination cracking.

Research advances in online-monitoring methods of manufacturing process for fiber reinforced resin matrix composites

GAO Ruijie, QI Lei, GUO Ruiqi, GU Yizhuo, WANG Shaokai, LI Min

2024, 0(12): 134-146. DOI: 10.19936/j.cnki.2096-8000.20241228.019

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Processing quality of fiber reinforced resin matrix composites is influenced by many factors, such as resin impregnation and flow, curing reaction, thermal and residual stresses. These processes are typically carried out within enclosed chambers or molds, which are complicated to control and optimize. Placing various sensors inside or outside composite parts for online-monitoring can obtain characteristic parameters of material and molding process that reflect the above physical and chemical changes. It can provide an important basis for the adjustment and optimization of process parameters and the research of composite molding process. This article aims to summarize online-monitoring methods for composite processing, which are commonly used in aerospace field, including fiber grating method, carbon nanotube sensor method, resin pressure online monitoring method, thin film pressure sensor method and dielectric analysis method. The implementation of these methods enables to obtain important information about molding process, such as temperature, strain, pressure, resin flow front, resin viscosity, and curing state. The acquisition of these information is of importance for eliminating molding defects and optimizing manufacturing processes. In addition, this article also discusses the combination of online-monitoring and digital technologies, and the existing problems and development trend of online-monitoring technology are pointed out.

Status and application in aerospace of advanced thermoplastic composite materials

ZHAO Miao

2024, 0(12): 147-152. DOI: 10.19936/j.cnki.2096-8000.20241228.020

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Advanced thermoplastic composite material is a new kind of promising composite for aeroplane structural parts application with the advantages of good recycling, reutilization, post forming, short processing cycle, high manufacturing efficiency and high toughness. In this paper, the main performance characteristics of resin matrix,thermoplastic prepreg for advanced thermoplastic composite material and the state of the arts in thermoplastic composite manufacturing were summarized. The applications of advanced thermoplastic composite material in overseas aviation equipment were introduced. The focus for research and development of advanced thermoplastic composite in the future on thermoplastic prepreg manufacture in high quality and high efficiency, automated tape placement combined with in-situ consolidation and automatic welding were also proposed.

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