Development of intimate contact during processing of carbon fiber reinforced Polyamide-6 tapes

Contact development between the surfaces of two tapes is considered as a critical step in processing carbon fiber reinforced thermoplastic composites. In this study, the development of intimate contact between carbon fiber reinforced Polyamide-6 (PA-6) tapes is investigated experimentally using consolidation experiments and X-ray computed tomography for quantitative contact characterization. The experimental results indicate that the development of intimate contact occurs in the range of seconds even when temperatures are only slightly above the melting temperature and applied pressures is in the range of 1-4 kPa. Experimental data are compared with the results of the two analytical models proposed by Lee and Springer as well as Yang and Pitchumani. Both models overestimate the time needed to reach full contact for the PA-6 tape. In comparison to previously investigated PEEK materials, PA-6 has a relatively low viscosity and the tapes possess a resin-rich layer near the surface, which seems to influence the contact development process. Besides the assumptions made for viscosity, the sensitivity to input parameters describing the surface topology strongly influence the model results and the accuracy of predictions.