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The ring spinning technology is widely used in the textile industry to produce high‐quality yarn. One of the challenges for higher productivity is the limited spindle speed due to friction in its conventional ring/traveler twisting system. However, it was recently shown that a superconducting magnetic bearing twisting system might overcome this limitation due to significantly reduced friction, which allows the use of higher spindle speeds and thereby increases productivity. To analyze the impact of speed increments on the yarn formation, it is crucial to model the yarn balloon dynamics. This is of particular importance as new challenges arise for such high‐speed processes, including the increase in yarn tension due to higher centrifugal forces and increased air resistance of the yarn itself. Therefore, in this work, a model based on a chain of springs and masses as an alternative to traditional continuous models was developed. In the proposed model, each mass corresponds to a yarn segment, while the springs represent the interactions between adjacent segments. This discrete approach allows for a simplified simulation of the three‐dimensional yarn balloon dynamics, leading to a reduced computational load, which allows to analyze the yarn path more easily under different conditions. [ABSTRACT FROM AUTHOR]

With the increased use of fibre reinforced composites (FRP), the design of new generation of composite structures with high stiffness and a ductile material behaviour is required to cope with complex load scenarios and high damage tolerances. This can be achieved, in particular, by a combination of conventional fibre-reinforced composites (FRP), which possess high stiffness and strength with metallic materials characterized by their high ductility and associated higher energy absorption capacity. Currently, there are no solutions for hybridisation of high performance filament yarns, metal filament yarns and thermoplastic filament yarns on micro level. Therefore, the main objective of this study is to develop a fibre hybrid composite based on hybrid yarn consisting of glass, steel and polypropylene filament yarns and to compare its tensile and impact properties with those of the composite reinforced only with glass filament yarn. The tensile and impact properties of the unidirectional hybrid composites produced from the developed multi-material hybrid yarn consisting of steel, glass and polypropylene filament yarns are compared with those of a non-hybrid composite reinforced exclusively with glass filament yarn. The results show that by hybridising with steel fibres a characteristic post-failure behaviour can be achieved, so that the developed multi-material hybrid yarns have a high potential for use in composites with high crash and impact performance requirements, where safety demands are essential. [ABSTRACT FROM AUTHOR]

The aim of this research is to improve the impact strength of thermoplastic composites manufactured from recycled carbon fiber (rCF). For this purpose, the development of a novel multi-material, micro-scale hybridized and low-cost hybrid yarn by blending aramid fibers with rCF and polyamide 6 (PA 6) fibers through the processing route of carding, drawing and flyer spinning is reported in this paper. In addition, two other hybrid yarns were produced from rCF/PA 6 and aramid/PA 6 for comparison with the multi-material rCF/aramid/PA 6 hybrid yarn. Finally, the tensile, flexural and impact properties of composites based on the developed rCF/aramid/PA 6 multi-material hybrid yarn were compared with those of composites reinforced only with rCF and aramid fiber. The results of the Charpy impact test showed that the inclusion of 24 volume percentage aramid fiber increased the impact strength by 70% compared to the composite reinforced with rCF alone. The multi-material hybrid yarn consisting of rCF/aramid/PA 6 fibers shows good potential for designing a hybrid composite with tailored tensile, flexural and impact resistant properties. [ABSTRACT FROM AUTHOR]

Because of a growing demand and usage of carbon fiber, effective methods to re-use waste and recycled carbon fiber recoverable either from process scraps or from end-of-life components are attracting increased attention. The development of different hybrid yarn structures consisting of recycled carbon fiber and thermoplastic fibers (recycled carbon fiber content approx. 50% by weight) for thermoplastic composites have been reported earlier. Yarns with high recycled carbon fiber content (>90% by weight) required for thermoset composites are still not realizable due to high shortening in recycled carbon fiber length (≥70%) during different processing steps of spinning. The reason lies in low shear strength, smooth fiber surface and high brittleness of recycled carbon fiber. Second, a lack of crimp in recycled carbon fiber leads to drafting errors during the drawing and spinning process. In this paper, the spinning limit regarding the core to sheath ratio of noble yarns with a recycled carbon fiber content greater than 90% by weight based on friction spinning technology for thermoset composites is reported. Slivers of recycled carbon fiber solely required for the development of yarns are produced on carding and drawing machines optimized for the gentle processing of recycled carbon fiber. Furthermore, different spinning parameters such as spinning drum speed and suction air pressure are investigated and their effect on tensile properties of yarn is analyzed. The results show that yarns with high recycled carbon fiber content (>90% by weight) can be produced with reproducible quality on the DREF-3000 friction spinning machine. [ABSTRACT FROM AUTHOR]

This article reports the results of investigations carried out to produce yarns consisting of staple carbon fiber (CF) obtained from process waste for the manufacturing of composites suitable especially for thermoset applications. For this purpose, a comparative analysis is done on processability between 100% staple CF and 60 weight% staple CF mixed with 40 weight% PVA fibers in carding, drawing and spinning process. The hybrid yarns are produced by varying twist level. The PVA fibers of the hybrid yarn are then dissolved using hot water treatment. The mechanical properties of yarns consisting of 100% staple CF and hybrid yarns consisting of staple CF and PVA before and after hot water treatment are investigated. Furthermore, test specimen is also prepared by impregnating 100% staple CF yarn and the hybrid yarns (after the dissolving of PVA) with epoxy resin. The results of the tensile test of the yarns in consolidated state reveals that the hybrid yarn produced with 80 T/m after hot water treatment exhibits approximately 75% of the tensile strength of virgin filament tow, and it is expected that the hybrid yarns can be applied for the manufacturing of thermoset based composites for load bearing structures.

This paper aims to conduct theoretical modeling of tensile properties of thermoplastic composites developed from novel unidirectional recycled carbon fiber tapes. Unidirectional recycled carbon fiber tape structure is an innovative, sustainable and cost-efficient prepreg structure designed to develop carbon fiber reinforced plastics with the highest resource efficiency. In order to do modeling, existing theoretical models of tensile properties of unidirectional composites were reviewed in the first part of this paper. Subsequently, reviewed theoretical models were further modified by considering the tensile properties of fibers, fiber length, fiber orientation, fiber volume content and short fiber content to predict the tensile properties of composites based on novel tape structure. The results of this study reveal that the proposed theoretical models are in good agreement with the experimental results. [ABSTRACT FROM AUTHOR]

With the increased use of fiber-reinforced composites (FRPs), the design of a new generation of composite structures with high stiffness and a ductile material behavior is required to cope with complex load scenarios and high damage tolerances. This can be achieved, in particular, by a combination of conventional FRPs, which possess high stiffness and strength, with metallic materials characterized by their high ductility and associated higher energy absorption capacity. Currently, there are no solutions for the hybridization of high-performance filament yarns, metal filament yarns or thermoplastic filament yarns at the micro level. Therefore, the aim of this paper is the hybridization of multi-fiber components intermixed at the micro scale. For this purpose, three hybridization processes were investigated. They are conventional air-jet technology, air-jet technology based on a modified air nozzle and an additional pre-spreading device and a process based on a newly developed multi-level-intermixing device. The effect of different processing parameters, such as air pressure, air nozzle and type of manufacturing, on the tensile properties, appearance and damage of multi-material hybrid yarn was analyzed. The results show that the developed multi-material hybrid yarns have high potential for use in composites with high requirements for crash and impact properties. [ABSTRACT FROM AUTHOR]

The implementation of a Superconducting Magnetic Bearing (SMB) system is a promising solution for the problem of friction exhibited in the twisting elements of the conventional ring‐spinning process. This research focuses on the development of a dynamical model with six degrees of freedom of the Permanent Magnet (PM) ring used in an SMB system for a high‐speed ring spinning process. The modeling takes into account the magnetic forces and torques that enable the magnetic levitation of the PM ring. Experimental tests allow the identification of unknown parameters of the model and the validation is done through simulations. [ABSTRACT FROM AUTHOR]

Composites based on e.g. randomly oriented nonwovens and injection moulded structures from discontinuous carbon fibre (CF), which are processed industrially exhibit low tensile strengths of 200–300 MPa and 400 MPa, respectively. In contrast, composites based on twisted hybrid yarns from discontinuous CF and thermoplastic fibre show higher tensile strengths such as 1150 MPa. Reasons are improved fibre orientation and higher fibre volume content. However, tensile strength is still lower than that of uni-directional carbon fibre reinforced composites (CFRP) based on continuous filament yarn, which is around 1560 MPa. The reason is a low fibre orientation due to yarn twisting and high fibre shortening, which occurs throughout the yarn manufacturing process. As mechanical properties of composites largely depend on fibre orientation and length, there is a high potential to achieve higher mechanical properties in CFRP by ensuring gentle processing of CF and reducing yarn twist. However, due to brittleness and smooth surface of CF, spinning of yarns with low twist (<60 T/m (twist per meter)) is challenging. In order to exhaust the potential of hybrid yarns, a semi-industrial process chain to produce hybrid yarns while ensuring gentle processing of discontinuous CF (fibre length 100 mm) and polyamide 6 fibres (fibre length 80 mm) at significantly low level of twist 20 T/m is reported in this paper. Carbon fibre reinforced composite manufactured from these hybrid yarns show high tensile strength (1453 ± 27 MPa), Young's modulus (94 ± 6 GPa), flexural strength (1090 ± 41 MPa) and flexural modulus (98 ± 5 GPa). [ABSTRACT FROM AUTHOR]

Technological developments in the processing of staple carbon fiber disclosed that producing hybrid yarn with improved homogeneity, uniformity, compactness and orientation can fully utilize the potential in high-performance composites. Therefore, developing hybrid yarn structures through yarn formation technology has become an emerging trend in the past few years. The present paper aims to highlight the recent development in the yarn formation technology for producing innovative yarn structures from staple carbon and thermoplastic fibers for high-performance fiber-reinforced plastics. For this purpose, pre-spinning, spinning and post-spinning operations of yarn formation technology are reviewed to technological aspects and processing of staple carbon fiber. Furthermore, recent developments in developing flyer, friction and wrap-spun hybrid yarn for high-performance composites are also presented in this paper. An attempt is carried out to develop the relationship between hybrid yarn structures and composite properties. The comparison of tensile properties of thermoplastic plastic composites shows that composite based on hybrid yarn structure possesses 300% and 700% higher tensile strength compared to nonwovens and injection molding composites. [ABSTRACT FROM AUTHOR]

Textile reinforcements have established themselves as a convincing alternative to conventional steel reinforcements in the building industry. In contrast to ribbed steel bars that ensure a stable mechanical interlock with concrete (form fit), the bonding force of smooth carbon rovings has so far been transmitted primarily by an adhesive bonding with the concrete matrix (material fit). However, this material fit does not enable the efficient use of the mechanical load capacity of the textile reinforcement. Solutions involving surface-profiled rods promise significant improvements in the bonding behavior by creating an additional mechanical interlock with the concrete matrix. An initial analysis was carried out to determine the effect of a braided rod geometry on the bonding behavior. For this purpose, novel braided rods with defined surface profiling consisting of several carbon filament yarns were developed and characterized in their tensile and bond properties. Further fundamental examinations to determine the influence of the impregnation as well as the application of a pre-tension during its consolidation in order to minimize the rod elongation under load were carried out. The investigations showed a high potential of the impregnated surface-profiled braided rods for a highly efficient application in concrete reinforcements. Hereby, a complete impregnation of the rod with a stiff polymer improved the tensile and bonding properties significantly. Compared to unprofiled reinforcement structures, the specific bonding stress could be increased up to 500% due to the strong form-fit effect of the braided rods while maintaining the high tensile properties. [ABSTRACT FROM AUTHOR]

Fiber–metal hybrid composites are widely used in high-tech industries due to their unique combination of mechanical, toughness and ductile properties. Currently, hybrid materials made of metals and high-performance fibers have been limited to layer-by-layer hybridization (fiber–metal laminates). However, layer-by-layer hybridization lacks in fiber to fiber mixing, resulting in poor inter-laminar interfaces. The objective of this paper was to establish the fundamental knowledge and application-related technological principles for the development and fabrication of air-textured commingled yarn composed of glass (GF), stainless steel (SS) and polyamide-6 (PA-6) filaments for fiber–metal hybrid composites. For this purpose, extensive conceptual, design and technological developments were carried out to develop a novel air-texturing nozzle that can produce an innovative metallic commingled yarn. The results show that an innovative metallic commingled yarn was developed using fiber–metal hybrid composites with a composite tensile strength of 700 ± 39 MPa and an E-modulus of 55 ± 7. This shows that the developed metallic commingled yarn is a suitable candidate for producing metal–fiber hybrid composites. [ABSTRACT FROM AUTHOR]

Recycling carbon fibers (rCF) for reuse is one approach to improve the sustainability of CFRP. However, until now, recycled carbon fiber plastics (rCFRP) had limited composite properties due to the microgeometry of the fibers, which made it difficult to use in load-bearing components. The production of hybrid yarns from rCF and PA6 fibers allows the fibers to be aligned. The geometric properties of the yarn and the individual fibers influence the mechanical properties of the composite. An approach for the modeling and simulation of hybrid yarns consisting of recycled carbon fibers and thermoplastic fibers is presented. The yarn unit cell geometry is modeled in the form of a stochastic fiber network. The fiber trajectory is modeled in form of helical curves using the idealized yarn model of Hearle et al. The variability in the fiber geometry (e.g., length) is included in form of statistical distributions. An additional compaction step ensures a realistic composite geometry. The created model is validated geometrically and by comparison with tensile tests of manufactured composites. With the validated model, multiple parameter studies investigating the influence of fiber and yarn geometry are carried out. [ABSTRACT FROM AUTHOR]

The processing of recycled carbon fibres (rCFs) into hybrid yarn constructions is a promising recycling option, converting rCF into products with added value. Along with fibre length and strength, the sizing of rCF crucially affects their processing behaviour and subsequent composite properties. This article reports on the influence of sizing on the processing properties of rCF by mixing with polyamide (PA) 6 fibres to form a hybrid yarn construction. Moreover, resulting composite properties were studied as well. Thus, commercially available CF with thermoplastic and thermoset matrix compatible sizing in addition to pyrolyzed rCF without sizing was used for the investigations presented in this article. Results revealed that different sizing strongly influence the processing of rCF and PA 6 into hybrid yarn constructions. The opening and bending behaviour of rCF bundles with different sizing varied during the carding process so that various degrees of fibre shortening occurred. As expected, the sizing developed for thermoplastic matrix enabled the highest tensile and flexural strengths in thermoplastic composites. These findings greatly contribute to the understanding of rCF processing from different or unknown sources on industrial scale. [ABSTRACT FROM AUTHOR]

Due to the increasing application of carbon fibre–reinforced plastics, the use of recycled carbon fibres can help reduce the tremendous amount of carbon fibre waste growing worldwide. In this context, the processing of longer recycled carbon fibres (>40 mm mean length) into hybrid yarn constructions offers a promising solution. The characterisation of recycled carbon fibre length is essential for textile processes. However, to suit the atypical fibre characteristics of recycled carbon fibres compared to standard natural or man-made-fibres, the development of an adequate measuring technique is required. Investigations on the state of the art suggest that an adapted fibrograph method might pose an appropriate measuring system. Therefore, new test equipment and an alternative image analysing method based on pixel greyscale values were developed. To enable a calibration process, different samples with cut carbon fibre from carded and drafted slivers were intensively tested and compared. In addition, an adapted reference method was investigated by combining single fibre measurement and image processing techniques. In a final step, recycled carbon fibres samples with unknown fibre length were tested. Results proved that the presented measuring system is adequate for the testing of longer recycled carbon fibres in webs or slivers. All measured values were close to the measured reference length values (deviation ±4%). [ABSTRACT FROM AUTHOR]

The processing of waste carbon fibre on carding machine for the developments of nonwovens, tapes and hybrid yarn structures is an emerging trend. These structures are widely used to enhance the performance efficiency of recycled carbon fibre reinforced thermoplastic composites. The aim of the research presented in this study is to process waste carbon fibre on a carding machine and to investigate the influence of different carding parameters on waste carbon fibre. For this purpose, card slivers composed of waste carbon and polyamide fibres were developed on a double cylinder card machine by varying technical parameters. Then, effect of these parameters on card sliver quality was assessed in terms of fibre orientation, fibre length and sliver cohesion force. Results revealed that fibre orientation and fibre length is significantly affected by technological parameters carding zones, whereas the sliver cohesion force is significantly affected by the speed of feed roller and doffer. [ABSTRACT FROM AUTHOR]

The aim of this paper is to highlight recent developments in the processing of waste carbon fibre for thermoplastic composites. Initially, injection moulding and nonwoven technologies have been used to integrate waste carbon fibres into fibre-reinforced thermoplastic composites. Recently, tape and hybrid yarn spinning technologies have been developed to produce tape and hybrid yarn structures from waste carbon fibre, which are then used to manufacture recycled carbon fibre-reinforced thermoplastics with much higher efficiency. The hybrid yarn spinning technologies enable the development of various fibrous structures with higher fibre orientation, compactness and fibre volume fraction. Therefore, thermoplastic composites manufactured from hybrid yarns possess a good potential for use in load-bearing structural applications. In this paper, a comprehensive review on novel and existing technologies employed for the processing of waste carbon fibre in addition to different quality aspects of waste carbon fibre is presented. [ABSTRACT FROM AUTHOR]

Due to the increasing application of carbon fibre-reinforced plastics, the use of recycled carbon fibres can help reduce the tremendous amount of carbon fibre waste growing worldwide. In this context, the processing of longer recycled carbon fibres (>40 mm mean length) into hybrid yarn constructions offers a promising solution. The characterisation of recycled carbon fibre length is essential for textile processes. However, to suit the atypical fibre characteristics of recycled carbon fibres compared to standard natural or man-made-fibres, the development of an adequate measuring technique is required. Investigations on the state of the art suggest that an adapted fibrograph method might pose an appropriate measuring system. Therefore, new test equipment and an alternative image analysing method based on pixel greyscale values were developed. To enable a calibration process, different samples with cut carbon fibre from carded and drafted slivers were intensively tested and compared. In addition, an adapted reference method was investigated by combining single fibre measurement and image processing techniques. In a final step, recycled carbon fibres samples with unknown fibre length were tested. Results proved that the presented measuring system is adequate for the testing of longer recycled carbon fibres in webs or slivers. All measured values were close to the measured reference length values (deviation ±4%). [ABSTRACT FROM AUTHOR]

Due to their excellent strength, rigidity, and damping properties, as well as low weight, carbon fiber reinforced composites (CFRCs) are being widely used for load bearing structures. On the other hand, with an increased demand and usage of CFRCs, effective methods to re-use waste carbon fiber (CF) materials, which are recoverable either from process scraps or from end-of-life components, are attracting increased attention. In this paper, hybrid yarns consisting of waste staple CF (40 and 60 mm) and polyamide 6 staple fibers (60 mm) are manufactured on a DREF-3000 friction spinning machine with various process parameters, such as spinning drum speed, suction air pressure, and core–sheath ratio. The relationship between different textile physical properties of the hybrid yarns, such as tensile strength, elongation, and evenness with different spinning parameters, core–sheath ratio, and input CF length is revealed. [ABSTRACT FROM AUTHOR]

The fundamental research work about the superconducting magnetic bearing (SMB) twisting system provides huge potential to eliminate the most important limitation of productivity, that is, the friction in the ring traveler system of the existing ring spinning process. As a continuity of the research work, the functionality of the SMB spinning has been carried out with different angular spindle speeds, yarn counts, and materials in order to determine the influence of the SMB technology. The current paper presents a comparative investigation of the yarn properties, such as yarn tenacity, yarn elongation, yarn evenness, microscopic views, etc., between conventional and SMB ring spun yarn. The intensive analysis confirms that the SMB system enables one to produce satisfactory yarn quality similar to that of conventional ring spun yarn up to 15,000 rpm. The influence of conventional and SMB spinning processes on yarn properties has been further analyzed statistically using an analysis of variance. [ABSTRACT FROM AUTHOR]

This article reports the results of investigations carried out to produce yarns consisting of staple carbon fiber (CF) obtained from process waste for the manufacturing of composites suitable especially for thermoset applications. For this purpose, a comparative analysis is done on processability between 100% staple CF and 60 weight% staple CF mixed with 40 weight% PVA fibers in carding, drawing and spinning process. The hybrid yarns are produced by varying twist level. The PVA fibers of the hybrid yarn are then dissolved using hot water treatment. The mechanical properties of yarns consisting of 100% staple CF and hybrid yarns consisting of staple CF and PVA before and after hot water treatment are investigated. Furthermore, test specimen is also prepared by impregnating 100% staple CF yarn and the hybrid yarns (after the dissolving of PVA) with epoxy resin. The results of the tensile test of the yarns in consolidated state reveals that the hybrid yarn produced with 80 T/m after hot water treatment exhibits approximately 75% of the tensile strength of virgin filament tow, and it is expected that the hybrid yarns can be applied for the manufacturing of thermoset based composites for load bearing structures. [ABSTRACT FROM AUTHOR]

High-performance yarns such as aramid fibers are nowadays used to reinforce composite materials due to their advantageous physico-chemical properties and their low weight. They are also resistant to heat and fire. Para-aramid filament yarns (p-AFs) wound on a cylindrical dyeing package have been silvered successfully by means of a newly developed wet-chemical filament yarn metallization process on a laboratory scale. The surface morphology of untreated and silvered p-AF was determined by means of scanning electron microscopy. The chemical structure of the surfaces (contents of carbon, oxygen, nitrogen and silver) was determined by means of energy-dispersive X-ray spectroscopy (EDX). The eliminated and newly formed groups of p-AF before and after silvering were detected by infrared spectroscopy (Fourier transform—attenuated total reflectance). After metallization, the silver layer thickness, the mass-related silver content and washing and rubbing fastness were assessed. Furthermore, textile-physical examinations concerning Young's modulus, elongation at break and electrical conductivity were performed. Subsequently, the electrically conductive p-AFs were integrated in thermoset composite materials reinforced by glass fibers and para-aramid. [ABSTRACT FROM AUTHOR]

The aim of this paper was to investigate the effect of carbon fibre (CF) length and preparation prior to carding on the mechanical properties of hybrid yarns as well as composites consisting of CF and polyamide 6 (PA 6). The hybrid yarns are manufactured using an optimised process route of carding and drawing with a flyer machine from virgin staple CF (40/60/80/100 mm) and PA 6. In order to explore the effect of fibre preparation on the mechanical properties of hybrid yarns as well as composites, virgin staple CF and PA 6 fibres were prepared by varying the mixing type prior to the carding process. For this purpose, the fibres were mixed either by a fibre-opening device or supplied directly to the carding machine without prior mixing. The CF content of the card webs produced is kept at 50 volume %. Hybrid yarns were produced with a twist of 102 twist/m and then thermoplastic unidirectional (UD) composites were manufactured from them. The investigations revealed the influence of the input CF length and mixing type on the mechanical properties of hybrid yarns and thermoplastic UD composites. [ABSTRACT FROM AUTHOR]

This paper presents a mathematical model to predict the distribution of yarn tension and the balloon shape as a function of spindle speed in the ring spinning process. The dynamic yarn path from the delivery rollers to the winding point on the cop has been described with a non-linear differential equation system. These equations have been integrated with a Runge–Kutta method using MATLAB software. Since the numerical solution of the equations strongly depends on initial values, an algorithm of sensitivity analysis has been developed to predict the right choice of initial values in order to find a stable solution. For model validation purposes, the yarn tension has been measured between delivery rollers and yarn guide. Furthermore, a high-speed camera has been used to capture the balloon shape at different spindle angular velocities in order to compare the theoretically determined balloon shape with the one that actually occurs on the machine. [ABSTRACT FROM AUTHOR]

For the manufacturing of load-bearing carbon fibre reinforced plastics (CFRP) made from staple carbon fibres (CF), statements of the CF fibre length in the composite are essential. However, no suitable fibre length measuring method is currently available for long staple CF over 60 mm. The aim of this study is the development of an effective method for characterization of the fibre length distribution of long staple CF. For this method, a fibre beard specimen is extracted from a sliver manufactured from 80 mm staple CF, which is then scanned. Greyscale values densities (GD) of the individual length classes are determined from the scanned images, which correspond to the number of fibres per length class. From the proportion of all length classes, a span length diagram and staple fibre length diagram can be compiled. The results show the good potential of the method developed for the fibre length measurement of long staple CF. [ABSTRACT FROM AUTHOR]

Twist plays an important role to impart tensile strength in yarn during the spinning process. In the most widely used ring-spinning machine for short staple yarn production, a combination of ring and traveler is used for inserting twist and winding the yarn on cops. The main limitation of this twisting mechanism is the friction between the ring and traveler, which generates heat at higher speed and limits the productivity. This limitation can be overcome by the implementation of a magnetic bearing system based on superconducting technology, which replaces completely the existing ring/traveler system of the ring-spinning machine. This superconducting magnet bearing consists of a circular superconductor and permanent magnet ring. After cooling the superconductor below its transition temperature, the permanent magnet ring levitates and is free to rotate above the superconductor ring according to the principles of superconducting levitation and pinning. Thus the superconducting magnetic bearing (SMB) ensures a friction-free operation during spinning and allows one to increase spindle speed and productivity drastically. The yarn properties using the SMB system have also been investigated and they remain nearly identical to those of conventional ring yarns. [ABSTRACT FROM PUBLISHER]

The auto-leveling system of a modern draw frame is widely used for conventional fibers to develop homogeneous, uniform, and defect free drawn slivers. This auto-leveling system also improves the quality of tapes and hybrid yarn structures by eliminating mass irregularities in hybrid sliver. However, the existing auto-leveling system exerts very high loads on feedstock, thus diminishing the quality of waste carbon in the delivered sliver. The aim of the present study was to process hybrid sliver based on waste carbon and polyamide fibers on a modern draw frame and modify the auto-leveling system to enable the damage-free processing of carbon fiber. For this purpose, hybrid card slivers were processed on an industrial draw frame with auto-leveling system. The different auto-leveling parameters, e.g., scan roller width and scan roller load, were modified and optimized for the uniform and damage-free processing of hybrid sliver. Results revealed that the scan roller load has a significant influence on the quality of waste carbon fiber in hybrid sliver. A uniform hybrid sliver ensures the reproducibility of unidirectional tapes and hybrid yarn at industrial scale, while simultaneously maintaining the quality of recycled carbon fiber-reinforced thermoplastics. [ABSTRACT FROM AUTHOR]

This paper presents an innovative, eco-friendly and sustainable tape manufacturing technology that transforms waste carbon and polyamide fibers into a new class of fibrous structure with unidirectional fiber orientation, termed "unidirectional tapes structure" for the fabrication of high performance composites. This novel technology imparts homogeneity, uniformity, orientation and thermal stability in unidirectional tapes structure that resemble conventional prepreg material. Unidirectional configuration of the tapes structure brings a revolution towards development of cost efficient carbon fiber composites for load bearing structural applications. This paper introduces the concept of tape manufacturing technology and highlights the modifications, optimization, and technological developments carried out to develop unidirectional tapes. The structural parameters that play a significant role in the properties of the high performance composite, such as fiber length, fiber orientation, fiber damage, and uniformity, were assessed during tape manufacturing. The results reveal composites fabricated from unidirectional tape structures with optimum parameters deliver tensile strength and modulus of 1370 ± 22 MPa and 85 ± 4 GPa, respectively. [ABSTRACT FROM AUTHOR]

The suitability of various spinning methods for a gentle production of hybrid yarns from recycled carbon fibers (rCF) was investigated comprehensively at the Institute of Textile Machinery and High Performance Material Technology (ITM), TU Dresden, Dresden/Germany. The results are discussed in this article. [ABSTRACT FROM AUTHOR]