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Self-resistance electric heating of shaped CFRP laminates: temperature distribution optimization and validation

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Abstract

The self-resistance electrical (SRE) heating method to cure the carbon-fiber-reinforced polymer (CFRP) parts possesses the advantages of rapid and volumetric heating, low energy consumption, and low asset investment. But the current SRE heating methods are difficult to uniformly cure the shaped CFRP parts due to the non-uniformly distributed Joule heat power in the parts with a varying cross-sectional area. In this paper, an optimized multi-zone SRE heating method is proposed, in which the uniform heating and curing process of the shaped CFRP part is firstly achieved. By optimizing the orientation of the rectangular zones, the local overheating caused by the voltage gradient and current diffusion between different zones is notably suppressed. Combined with the electro-thermal numerical analysis, the influence of the positional offset of electrodes in two adjacent zones on the temperature uniformity is investigated. Based on this, an automated zone discretization algorithm and the optimal selection method of the zone orientation are established. The proposed method is numerically and experimentally validated with the typical-shaped CFRP parts, and the results are compared with that of the existing SRE heating method. The proposed method realizes that the maximum in-plane temperature difference of shaped CFRP parts is reduced by more than 80%. This method significantly improves the temperature uniformity of shaped CFRP parts during the multi-zone SRE heating process, which provides a potential solution for high-quality and efficient curing of CFRP parts.

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Acknowledgements

The authors would like to acknowledge the team members, for their continuous support.

Funding

This work was supported by a major project of the National Natural Science Foundation of China (grant no. 52090052), National Natural Science Foundation of China (grant no. 51775261), and Postgraduate Research & Practice Innovation Program of Government of Jiangsu Province (KYCX18_0319); the authors sincerely appreciate the continuous support provided by our industrial collaborators.

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Yingxiang Shen, Shuting Liu, Qiangqiang Liu, Shuangquan Tao & Xiaozhong Hao

  2. School of Mechanical Engineering, Nanjing Institute of Technology, Nanjing, 211167, China

    Yong Lu

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  1. Yingxiang Shen
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Correspondence to Yong Lu.

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Shen, Y., Lu, Y., Liu, S. et al. Self-resistance electric heating of shaped CFRP laminates: temperature distribution optimization and validation. Int J Adv Manuf Technol 121, 1755–1768 (2022). https://doi.org/10.1007/s00170-022-09153-9

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