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Experimental and numerical investigations of a thermoplastic composite (carbon/PPS) thermoforming

For lightweight structural components, continuous fibre‐reinforced thermoplastic composites have demonstrated success in aerospace and defence applications. Their mechanical behaviour is a result of the possible sliding and interactions between the fibres, but the complex deformation mechanisms of this sheet are a main problem in the practical thermoforming process. In this context, a large experimental work was developed to analyse the behaviour of a 5‐harness satin weave carbon–polyphenylenesulfide (PPS) composite. Firstly, we started this work with a microscope observation of the sheet cross section and a thermo‐gravimetric analysis of carbon/PPS to understand the thermal condition in the forming process, the reinforcement (fibre and yarn) geometry and dimensions and the textile reinforcement architectures. Secondly, in high temperature conditions (at 320°C), static uniaxial and biaxial tensile tests were carried out. During these mechanical tests, we used a digital image stereo‐correlation technique to get full field displacement measurements and an infrared camera to measure the temperature in the surface of sample.