Dr.-Ing.

Janssen, Henning

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  • Publication
    Advanced production of thermoplastic composite pipes
    ( 2019)
    Schäkel, Martin
    ;
    Peters, Tido
    ;
    Janssen, Henning
    ;
    Brecher, Christian
    A novel system for thermoplastic composite tape winding was developed as part of the ambliFibre multinational research project. The system features multiple functionalities for improved quality and reliability in the manufacturing of safety-critical structures such as composite armours for unbonded flexible pipes.
  • Publication
    Data Collection and Analysis for the Creation of a Digital Shadow During the Production of Thermoplastic Composite Layers in Unbonded Flexible Pipes
    ( 2018)
    Schäkel, Martin
    ;
    McNab, John
    ;
    Dodds, Neville
    ;
    Peters, Tido
    ;
    Janssen, Henning
    ;
    Brecher, Christian
    Unbonded flexible pipes present a mature technology for the efficient recovery and transport of hydrocarbons offshore. The substitution of metallic reinforcement layers in the multilayered structure by thermoplastic fiber-reinforced polymer (FRP) presents a solution for self-weight issues of especially long pipes, as FRP materials display high specific strength and modulus while being resistant to external pressure and corrosion. The production of these layers is automated by the laser assisted tape winding process without the need of additional curing steps. During the manufacturing process, several data like process temperature and consolidation pressure are continuously monitored by non-contact sensors to ensure process stability without interfering in the consolidation process. To gain additional information about the temperature distribution within the multi-layered laminate, contact temperature sensors were introduced in the tape winding process. By this method the temperature of subjacent tapes can be assessed during the continued winding process. Additionally, this paper features a new approach of utilizing winding path data for relating the time-dependent sensor data to the exact position on the produced part. The visualization of path-dependent sensor data opens up possibilities of linking quality monitoring results to manufacturing insufficiencies and potential part defects.
  • Publication
    Joining of thermoplastic tapes with metal alloys utilizing novel laser sources and enhanced process control in a tape placement process
    ( 2017)
    Kukla, Christian
    ;
    Peters, Tido
    ;
    Janssen, Henning
    ;
    Brecher, Christian
    Automated laser assisted tape placement is an additive manufacturing technology for the production of composite parts. Composite parts are common in various markets. Especially the automotive sector has a demand for lighter and stronger materials. The combination of standard sheet metal materials and fiber reinforced plastics promises to deliver enhanced properties and performances over the separate materials themselves. This multi-material combination is classically done with mechanical connections. This paper addresses a direct in-situ approach of putting carbon fiber reinforced thermoplastic tapes directly onto pre-structured sheet metal parts and shows the prerequisites needed for achieving a consolidation between both materials.
  • Publication
    Efficient production of tailored structural thermoplastic composite parts by combining tape placement and 3d printing
    ( 2017)
    Janssen, Henning
    ;
    Peters, Tido
    ;
    Brecher, Christian
    Thermoplastic composites, such as organosheets and unidirectional tapes, have become more and more popular in recent years. In certain high volume applications, they are often combined with non-reinforced plastics in overmolding processes. However, for product development or customized parts, more flexible process chains for the production of continuous fiber-reinforced thermoplastic parts are required. The automated placement of continuous fiber-reinforced thermoplastic tapes is an additive manufacturing technology which can be used to produce load-optimized tailored blanks. These blanks can be formed and joined with 3d printed structures to complex, function integrated, customized hybrid thermoplastic structures without the need of expensive molds.
  • Publication
    System improvement for laser-based tape placement to directly manufacture metal / thermoplastic composite parts
    ( 2017)
    Peters, Tido
    ;
    Kukla, Christian
    ;
    Janssen, Henning
    ;
    Brecher, Christian
    The possibility to manufacture economic efficiently structural functionalized parts using high-volume suited processes is crucial to implement lightweight strategies and fulfil the economic and ecologic needs for responsible use of energy and resources. One key strategy to overcome current obstacles of long cycle times and high material costs is to combine metal and thermoplastic composites within one part. Thus, the advantage of having the right material in the right place to fulfil all requirements to the part is used. However, applied solutions to manufacture these kind of multi-material structures still lack in terms of flexibility, productivity, quality and ideal material utilization. One solution for overcoming these current obstacles is the application of the selective diode laser-based tape placement process to locally reinforce metallic parts aiming to generate an optimum weight, reinforcement and cost profile within the part. Key requirement to establish in-situ a sufficient joint between a textured metallic surface and the applied thermoplastic composite tape is the generation of a sufficient heat distribution in both joining partners. Achieving these required conditions becomes even more challenging as both joining partners have completely different thermo-physical and optical properties. Especially, the latter leads to difficulties when using conventional diode laser-based tape placement systems to consolidate tape locally on metal parts, as a local heat input into the metallic component cannot be sufficiently achieved by the diode laser system of these placement units. The present work deals with initial trials to locally reinforce textured metal surfaces using conventional diode laser-based tape placement. Based on these findings the work derives the concept for a novel laser-based tape placement system which considers the use of Philips VCSEL (Vertical cavity surface emitting laser) technology.
  • Publication
    In Serie lokal verstärken
    ( 2016)
    Brecher, Christian
    ;
    Janssen, Henning
    ;
    Buschhoff, Clemens
    ;
    Peters, Tido
  • Publication
    Selective high-speed tape placement using cut-on-the-fly for local reinforcement of GMT substrates towards a waste-reducing production of multi-material components
    ( 2016)
    Brecher, Christian
    ;
    Peters, Tido
    ;
    Janssen, Henning
    Cost-efficient production technologies for lightweight composite components are the key enabler for a broad range of application. Manufacturing technologies like laser-assisted tape placement offer the opportunity to produce thermoplastic multi-material composite parts with optimum reinforcement, weight and cost profile. By the selective tape placement and in-situ consolidation of continuous unidirectional fibre-reinforced thermoplastic tapes in predetermined locations of existing composite structures, composite parts can be efficiently and economically manufactured. Enhanced by the new manufacturing process route, the weight of components can be significantly reduced by the combination of different reinforcement fibres in one single structure. This allows the achievement of an optimised relation between performance and weight. As a key enabler for drastically reducing the waste as well as the production times during in-situ selective tape placement the findings presented in this paper focus on the system and process technology to make an add-&-cut-on-the-fly process possible. Further findings focus on the increase in the process velocity and the influence of the lay-up pattern when using selective laser-assisted tape placement for the local reinforcement of a high-volume-suited polyamide 6-based glass mat thermoplastic substrate material.