Statistical approach to optimize crashworthiness of thermoplastic commingled composites

A design of experiments analysis was developed to relate the processing conditions to the impact energy absorption capability of thermoplastic commingled composites. Based on low velocity impact test responses and statistical modeling, a factorial design was implemented to investigate the interaction of processing parameters with the polymer viscosity. The influence of thermal consolidation on materials performances were evaluated and quantified. The dataset was obtained according to the impact energy capability of carbon fiber/polyamide and carbon fiber/poly (ether-ether-ketone) commingled composites. The results identified the best combination of variables which improves crashworthiness of structural composites and leads to high impact energy absorption capabilities. The results revealed that the commingled composites crashworthiness strongly depends on the polymer yarn dispersion in the carbon fiber tow, that was identified and classified in different distribution patterns. This work represents a significant step towards manufacturing of thermoplastics composites with target structural performance. [Display omitted]