This project addresses the need for economical methods of processing, to final complex shapes, composite structural materials having high- temperature thermoplastic polymer matrices. The research includes development of the die-less forming process, a very innovative approach to the forming of materials containing continuous reinforcing fibers. Potential advantages of the die-less forming process include a great reduction in equipment size for large components, elimination of the cost and lead time for dies, and flexibility and automation in processing. The research also includes basic investigation of the phenomena and physical mechanisms governing the processing of thermoplastic composites to final complex shapes (especially those unique to thermoplastics), and the development of quantitative models to predict those phenomena during processing. This research encompasses infiltration and in-plane deformation behavior within individual plies, ply autohesion/delamination response (to be investigated in situ using fluorescence techniques, and including the possible accelerating effect on autohesion of concurrent deformation). The research will be conducted by an interdisciplinary team of researchers in collaboration with industry which should significantly advance the processing science and ensure technology transfer.
