Laser Cutting of Fibre Reinforced Plastic Composites

In this section

Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 30182

Objectives

Identify the current state-of-the art in laser material processing of FRPs
Determine the quality criteria required
Assess the quality of laser FRP cut surfaces with respect to heat affected zone, delamination, and laser cut kerf geometries

Project Outline

Laser cutting and drilling of fibre reinforced plastic composites (FRPs) has significant potential, given that it is a non-contact, precise, low heat-input, high-productivity process. Currently, however, laser machining of FRPs is not optimised and such processes are not commonly used by industry. One particular problem is the different absorption characteristics of the fibre and matrix constituents of FRPs. This project will develop a fundamental understanding of the interactions between the laser beam, the machining assist gas and FRP’s. This research will be performed with state-of-the-art fibre-delivered laser sources. It is expected that a key technology-enabling output of this project will be a new nozzle design and process monitoring techniques, which will enable lasers to achieve the required cut quality in FRPs and, consequently, be considered as a viable production tool.

Relevant Industry Sectors

Industry Need

Fibre reinforced plastic composites (FRPs) are increasingly being adopted as high-performance engineering materials due to their exceptional specific strength and fatigue and corrosion resistance, in comparison with metallic alternatives. The automotive and commercial aerospace industry, in particular, are leading the way in introducing FRPs, as evidenced by the Boeing 787 and Airbus A350XWB, both consisting of approximately 50% composites by weight. This level of utilisation represents a significant increase on the airframes’ predecessors and is being driven by socio-economic pressures relating to CO2 emissions and fuel efficiency.

Even though FRPs may be produced in near-net-shape form, they inevitably require cutting and drilling (ie machining) operations. Mechanical cutting methods are commonly used but these require high tool forces and there is significant tool wear. Waterjet cutting has recently been investigated but delamination effects and the need for mechanically drilled pilot holes must be overcome.