Non-crimp Fabric Composites: Manufacturing, Properties and Applications

Non-crimp fabric (NCF) composites are reinforced with mats of straight (non-crimped) fibres, giving them such advantages as strength, ease of handling and low manufacturing costs. Non-crimp fabric composites provides a comprehensive review of the use of NCF composites, their manufacture and applications in engineering.

Part one covers the manufacture of non-crimp fabrics, including also topics such as structural stitching and automated defect analysis. Part two goes on to discuss the manufacture of non-crimp fabric composites, with chapters covering such topics as deformability and permeability of NCF. Part three focuses on the properties of NCF composites, with chapters on stiffness and strength, damage progression and fatigue. Finally, part four covers the applications of NCF composites, including chapters on the aerospace and automotive industries as well as wind turbines and helicopter applications. The book concludes with a discussion of cost analysis of NCF composites in engineering applications.

With its distinguished editor and international team of expert contributors, "Non-crimp fabric composites" is an essential reference for composite manufacturers and structural and mechanical engineers in industries using NCF composites, as well as academics with a research interest in the field.

Key features:

- provides a comprehensive review of the use of NCF composites, their manufacture and applications in engineering
- reviews the manufacture of non-crimp fabrics, including also topics such as structural stitching and automated defect analysis
- examines the properties of NCF composites considering stiffness and strength, damage progression and fatigue
- highlights the applications of NCF composites, featuring the aerospace and automotive industries as well as wind turbines and helicopter applications

PART 1: MANUFACTURING OF NON-CRIMP FABRICS

Production of non-crimp fabrics for composites
A Schnabel and T Gries, Institut für Textiltechnik (ITA) of RWTH Aachen University, Germany
- Introduction
- Warp-knitted non-crimp fabric (NCF)
- Weft-knitted NCF
- Non-crimp woven fabrics
- 3D woven and non-interlaced NCF
- Fixation by adhesion
- Comparison of production technologies
- Future trends
- Acknowledgements
- References

Standardisation of production technologies for non-crimp fabric composites
F Kruse and T Gries, Aachen University, Germany
- Introduction
- Classification and standardisation of non-crimp fabric (NCF) production methods
- Outstanding patents of existing machines for the production of NCFs
- The “Hexcel patent” – EP 0972102 B1
- Product patents in the production of NCFs
- Immobilization of adhesive on the surface of semi-finished textile products (DE 102008004112 A1)
- References

Structural stitching of non-crimp fabric preforms for composites
P Mitschang, Institut fuer Verbundwerkstoffe GmbH, Germany
- Introduction
- Threads for structural stitching technology
- Stitching technology and sewing machines
- Quality aspects for structural stitching
- Applications and future trends
- References

Understanding and modelling the effect of stitching on the geometry of non-crimp fabrics
S V Lomov, Katholieke Universiteit Leuven, Belgium
- Introduction
- General parameters of the fibrous plies
- Geometry of the stitching
- Distortions of fibres in the plies
- Change of the geometry after shear
- Geometrical model of NCF
- Conclusion
- References

Automated analysis of defects in fibre placement in non-crimp fabrics for composites
M Schneider, Toho Tenax Europe GmbH, Germany
- Motivation
- Quality characteristics of non-crimp fabric (NCF)
- Quality analysis of NCF by digital image analysis
- Future trends
- References

PART 2: MANUFACTURING OF NON-CRIMP FABRIC COMPOSITES

Deformability of textile performs in the manufacture of non-crimp fabric composites
S V Lomov, Katholieke Universiteit Leuven, Belgium
- Introduction
- Shear
- Biaxial tension
- Compression
- Bending
- Conclusion
- References

Modelling the deformability of biaxial non-crimp fabric composites
P Harrison, University of Glasgow, UK, W-R Yu, Seoul National University, Korea and A C Long, University of Nottingham, UK
- Introduction
- Behaviour of fabric architecture on the shear and draping behaviour of non-crimp fabrics (NCFs)
- Modelling strategies for NCF forming
- Energy-based kinematic mapping
- Finite element modelling of forming for NCFs
- Future trends
- Further information and advice
- References

Permeability of non-crimp fabric preforms
R Loendersloot, University of Twente, The Netherlands
- Introduction
- Experimental permeability results
- Geometric effects
- Deformation and permeability
- Conclusions
- Acknowledgements
- References
- Appendix: Nomenclature

Understanding variability in the permeability of non-crimp fabric composite reinforcements
A Endruweit and A C Long, University of Nottingham, UK
- Introduction
- Material characterisation
- Permeability measurement
- Modelling and simulation
- Future trends
- References

Modelling of the permeability of non-crimp fabrics for composites
B Verleye, S V Lomov and D Roose, Katholieke Universiteit Leuven, Belgium
- Introduction
- Numerical simulation
- Experimental validation
- Parametric study
- Influence of shear
- Conclusion
- Acknowledgements
- References

PART 3: PROPERTIES OF NON-CRIMP FABRIC COMPOSITES

Mechanical properties of non-crimp fabric (NCF) based composites: stiffness and strength
S V Lomov, T Truong Chi and I Verpoest, Katholieke Universiteit Leuven, Belgium
- Introduction
- Materials and composite production
- Test procedures
- Mechanical properties of non-crimp fabric (NCF) composites
- Mechanical properties of composites based on sheared MMCF
- Damage development in B2 (0°/90°) laminates
- X-ray radiography
- Damage initiation in non-sheared and sheared materials
- Conclusions
- References

Damage progression in non-crimp fabric composites
E Marklund, J Varna and L E Asp, Luleå University of Technology, Sweden
- Introduction
- Damage progression in non-crimp fabric (NCF) composites due to in-plane loading
- Damage progression in impacted NCF composites
- Conclusions
- References

Fatigue in non-crimp fabric composites
K Vallons, Katholieke Universiteit Leuven, Belgium
- Introduction
- Fatigue in non-crimp fabric (NCF) composites
- Post-fatigue residual properties
- Conclusions and open questions
- References
- Appendix

Mechanical properties of structurally stitched non-crimp fabric composites
N Himmel, Institut für Verbundwerkstoffe GmbH (Institute of Composite Materials) and H Heß, BASF Engineering Plastics Europe, Germany
- Introduction
- Materials and stitching configurations
- Characterization of structurally stitched NCF laminates
- Simulation of mechanical behaviour of structurally stitched laminates
- Conclusions and future trends
- References

Predicting the effect of stitching on the mechanical properties and damage of non-crimp fabric composites: finite element analysis
D S Ivanov, S L Lomov and I Verpoest, Katholieke Universiteit Leuven, Belgium
- Introduction
- Representative volume element (RVE) of non-crimp fabric (NCF) composites
- Elastic analysis
- Damage accumulation in NCF composites
- Conclusions
- References

Modelling drape, stress and impact behaviour of non-crimp fabric composites
A K Pickett, University of Stuttgart, Germany
- Finite element (FE) methods for drape, stress and impact analysis
- Laminate analysis and FE stiffness for non-crimp fabric (NCF)
- FE methods for infusion analysis
- Draping analysis and FE simulation
- Infusion simulation
- Stiffness and failure
- Impact and failure
- References

Modelling stiffness and strength of non-crimp fabric composites: semi-laminar analysis
E Marklund, J Varna and L E Asp, Luleå University of Technology, Sweden
- Introduction
- Stiffness models
- Strength models for non-crimp fabric (NCF) composites
- Conclusions
- References

PART 4: APPLICATIONS OF NON-CRIMP FABRIC COMPOSITES

Aerospace applications of non-crimp fabric composites
P Middendorf and C Metzner, EADS Deutschland GmbH, Germany
- Introduction
- Aeronautic requirements
- Application examples
- Future trends
- References

Non-crimp fabric: preforming analysis for helicopter applications
F Dumont and C Weimer, Eurocopter Deutschland GmbH, Germany
- Introduction
- Preform techniques for non-crimp fabrics (NCFs)
- Main NCF deformation mechanism observed during preforming
- Preforming defect analysis
- Conclusion and future trends
- References

Automotive applications of non-crimp fabric composites
B Sköck-Hartmann and T Gries, Aachen University, Germany
- Introduction
- Applications of non-crimp fabrics (NCF) in the automotive industry
- Research and development for the use of NCF in automotive applications
- Future trends
- Conclusion
- References

Non-crimp fabric composites in wind turbines
G Adolphs and C Skinner, OCV Technical Fabrics, Belgium
- Introduction
- Development of non-crimp fabric (NCF) composites in wind energy
- NCF materials used in Nacelle construction
- Future trends
- References

Cost analysis in using non-crimp fabric composites in engineering applications
P Schubel, University of Nottingham, UK
- Introduction
- Costing methodologies: current approaches
- Technical cost modelling
- Effect of production volume
- Case study: 40m wind turbine blade shell
- Acknowledgements
- References

Stepan Lomov is a Professor in the Department of Metallurgy and Material Engineering at the Katholieke Universiteit Leuven, Belgium.

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