Assessing residual stress redistribution during annealing in thick thermoplastic composites using optical fiber sensors

In thick thermoplastic composite laminates, nonuniform temperature and cooling rate distribution arises in the through-thickness direction during cost-effective high-rate manufacturing processes. Annealing is often carried out after molding to homogenize degree of crystallinity (DOC) and to reduce residual stress. Even though the change in the residual stress/strain distribution occurring inside thick laminates by this heat treatment is practically important, the changing process and the detailed mechanism are not sufficiently clarified. This present study addresses development and redistribution behavior of residual stress through both molding and annealing using multiple optical fiber sensors deployed in the thickness direction. This article begins by explaining about process monitoring of thick laminates to discuss process-induced strain distribution depending on cooling conditions during molding. Next, strain monitoring is performed during annealing, and the strain change caused by cold crystallization is clarified. Finally, the residual stress distribution is evaluated by a transverse three-point bending test, and the validity of the redistribution mechanism deduced from the strain measurement is confirmed.