An overview on fabrication of three-dimensional woven textile preforms for composites

Abstract

There are various manufacturing processes for the interlacement of yarns to produce three-dimensional (3D) fabric structures as preforms for textile composites. The manufacturing route is determined by the end-use of composites and therefore the composite industry does not solely rely on one method but a selection of methods for fabric formation. This paper attempts to make a comprehensive overview on fabrication methods that can be used for making 3D textile woven preforms for composites. There are many different views on what 3D woven fabrics are, but one common understanding is that 3D fabrics must have substantial dimension in the thickness direction formed by layers of fabrics or yarns. In this paper we classify 3D woven textiles into those that can be manufactured on the conventional weaving technology and those that require specially made weaving machines/devices. This paper attempts to provide useful information for both the textile and composite engineers in developing textile composites for advanced applications.

Keywords

Composites 3D fabric formation fabrication fibre manufacture weaving yarn

Get full access to this article

View all access options for this article.

References

Long A (ed.) Design and manufacture of textile composites. Cambridge: Woodhead, 2005.

Chen X. and Sun D. Textile materials in personal protection equipment for the police and military personnel. J of Xi’an Polytech Univ 2009; 23: 67-74.

Chen X. and Tayyar AE Engineering, manufacture and measurement of 3D domed woven fabrics . Text Res J 2003; 73: 375-380.

Chen X. and Hearle JWS. Developments in design, manufacture and use of 3D woven fabrics. In: Proceedings of TEXCOMP9 (International Conference on Textile Composites) , University of Delaware, 2008.

Ko FK 3D textile reinforcements in composite materials. In: Mirvete A (ed.) 3D textile reinforcements in composite materials . Cambridge: Woodhead, 1999.

Mohamed MH Recent advances in 3D weaving. In: Proceedings of the 1st World Conferences in 3D Fabrics and Their Applications, Manchester , 2008.

Khokar N. Second-generation woven profiled 3D fabrics from 3D-weaving. In: Proceedings of the 1st World Conferences in 3D Fabrics and Their Applications, Manchester, 2008.

Mirvete A (ed.) 3D textile reinforcements in composite materials. Cambridge: Woodhead, 1999.

Scardino FL Introduction to textile structures. In: Chou TW and Ko FK (eds) Textile structural composites. Covina, CA: Elsevier, 1989.

10.

Fukuta K. and Aoki E. 3D fabrics for structural composites. In: Proceedings of the 15th Textile Research Symposium. Philadelphia, PA , 1986.

11.

Khokar N. 3D-weaving: theory and practice. J Text Inst 2001; 92: 193-207.

12.

Solden JA and Hill BJ Conventional weaving of shaped preforms for engineering composites . Composite Part A 1998; 29: 757-762.

13.

Chen X. Technical aspect: 3D woven architectures. In: Proceedings of the NWTexNet 2007 Conference, Blackburn, 2007 .

14.

Chen X. and Potiyaraj P. CAD/CAM of the orthogonal and angle-interlock woven structures for industrial applications. Text Res J 1999; 69: 648-655.

15.

Banister M. and Herszberg I. Mechanical performance and modelling of 3D woven composites. In: Proceedings of the 4th International Conference on Automated Composites (ICAC95), Nottingham, 1995.

16.

Han Z. Production and tensile properties of 3D woven structures as composite reinforcements . MPhil Thesis, Department of Textiles, University of Manchester Institute of Science and Technology , 1999.

17.

Chen X. , Knox RT , McKenna DF and Mather RR Relationship between layer linkage and mechanical properties of 3D woven textile structures. In: Proceedings of the International Symposium on Textile and Composite Materials for High Functions . Finland, Tampere, 1992.

18.

Roedel C. and Chen X. Innovation and analysis of police riot helmets with continuous textile reinforcement for improved protection. J Inf Comput Sci 2007; 2: 127-136.

19.

Chen X. and Yang D. Use of 3D angle-interlock woven fabric for seamless female body armour, part I: ballistic evaluation. Text Res J 2010 ; 80: 1581-1588.

20.

Chen X. and Yang D. Use of 3D angle-interlock woven fabric for seamless female body armour, part II: mathematical modeling. Text Res J 2010 ; 80: 1589-1601.

21.

Grosicki Z. Watson’s advanced textile design: compound woven structures , 4th ed. London: Newnes-Butterworths , 1977.

22.

Newton N. , Georgallides C. and Ansell P. A geometrical model for a two-layer woven composite reinforcement fabric. Compos Sci Technol 1996; 56: 329-337.

23.

Georner D. Woven structure and design - part II: compound structures. Leeds: British Textile Technology Group , 1989.

24.

Chen X. , Ma Y. and Zhang H. CAD/CAM for cellular woven structures. J Text Inst 2004; 95: 229-241.

25.

Chen X. and Wang H. Modelling and computer aided design of 3D hollow woven fabrics. J Text Inst 2006; 97: 79-87.

26.

Koppelman E. and Edward AR Woven panel and method of making same. US Patent No. 3090406, 1963.

27.

Diesselback D. and Stahl D. Dimensionally stable composite material and process for manufacture thereof. Patent No. US4389447, 1983.

28.

Rheaume JA Three-dimensional woven fabric. Patent No. US3538957, 1970.

29.

Rheaume JA Multi-ply woven article having double ribs. Patent No. US3943980, 1976.

30.

Yip J. and Ng S-P. Study of three-dimensional spacer fabrics: physical and mechanical properties . J Mater Process Technol 2008 ; 206: 359-364.

31.

Van de Wiele. http://www.vandewiele.com/src/ (November 5, 2010)

32.

Takenaka K. and Eiji S. Woven fabric having multilayer structure and composite material comprising the woven fabric. Patent No. US5021283, 1988.

33.

Tan X. and Chen X. Parameters affecting energy absorption and deformation in textile composite cellular structures. Mater Des 2005 ; 26: 424-438.

34.

Chen X. , Sun Y. and Gong X. Design, manufacture, and experimental analysis of 3D honeycomb textile composites, part I: design and manufacture. Text Res J 2008; 78: 771-781.

35.

Busgen A. Woven fabric having a bulging zone and method and apparatus of forming same . Patent No. US6000442, 1999.

36.

Chen X. and Tsai L-J. Weaving of complex composite preforms of 3D shapes based on the origami principles . In: Proceedings of the 3rd Annual Conference of Northwest Composites Centre, Manchester, 2009.

37.

Smith MA CAD/CAM and geometric modelling algorithms for 3D woven multi-layer nodal textile structures. PhD Thesis, School of Materials, The University of Manchester, 2009

38.

Taylor LW Design and manufacture of 3D nodal structures for advanced textile composites. PhD Thesis, School of Materials, The University of Manchester , 2007.

39.

Lowe FJ Articles comprising shaped woven fabrics. Patent No. 4668545, 1987.

40.

Day GF , Robinson F. and Williams DJ Composite articles. Patent No. US4923724, 1990.

41.

Chen X. and Zhang H. Woven textile structures. Patent No. GB2404669, 2006.

42.

King RW Apparatus for fabricating three-dimensional fabric material. Patent No. US3955602, 1976.

43.

Mohamed MH and Zhang Z-H. Method of forming variable cross-sectional shaped three-dimensional fabrics . Patent No.US5085252, 1992.

44.

DTI Global Watch Mission Report. ‘HYBRIDMAT 4: advances in the manufacture of 3D preform reinforcement for advanced structural composites in aerospace: a mission to the USA http://www.ncn-uk.co.uk (2006).