Co-consolidation of CF/PEEK tape-preforms and CF/PEEK organo sheets to manufacture reinforcements in stamp-forming process

Abstract Co-consolidation is considered one effective joining method to allow novel types of integral structures to be manufactured. In this study, carbon fiber reinforced Polyether-Ether-Ketone partially consolidated tape preforms were co-consolidated with carbon fiber reinforced Polyether-Ether-Ketone organo sheets in stamp-forming process. Interlaminar bond quality of both joining partners is validated in double cantilever beam test. Results exhibit average interlaminar fracture toughness of 2.54 kJ/m2 for stamp-forming specimen, which exceeds interlaminar fracture toughness of reference samples manufactured in autoclave being 1.79 kJ/m2. Further examinations on specimen morphology and mechanical properties indicate distinct assignments to process characteristic cooling rates, which coincides with studies from literature. Accordingly, high cooling rates—as evident in stamp-forming process—are allocated to high toughness, low crystallinity and low bending modulus, causing high interlaminar fracture toughness. Investigations on laminate quality reveal maximum void content of 1.58%. Graphical Abstract