Title : Procedure for making flat thermoplastic composite laminates by automated fiber placement and their mechanical properties
Abstract:
Highly consistent quality and cost-effective manufacture of advanced composites can be achieved through automation. Automated Tape Laying (ATL) and Automated Fiber Placement (AFP) are the two technologies used to automate the layup of prepreg, which are applicable to produce composites in aerospace, automotive, renewable energy, and consumer goods. This paper presents research results in the field of automated fiber placement (AFP) systems dedicated to composite aerostructure manufacturing. The automated fiber placement (AFP) process and out-of-autoclave (OOA) technology are important in reducing the costs involved in making primary aerostructures ranging from simple flat parts to intricate three-dimensional parts. This combination promises fast, reliable, and cost-effective manufacturing. The products are commonly manufactured from a material called prepreg, which consists of fibers impregnated with polymer resins. The process comprises the automated laying of fiber-reinforced thermoplastic tapes to form a layer that merges with the previous one until the final laminate structure is built up. For the automated laying of the prepreg tape or fibers, a robotic installation is used to precisely lay the tape along predefined paths. The last research is directed towards enhancing the automated fiber placement AFP technologies of carbon fiber-reinforced thermoplastic (CFRTP) composite materials. One of the latest technological advancements in the AFP process is the introduction of continuous-wave high-power lasers for in-situ consolidation of parts at efficient rates with promising quality. In this paper, the AFP with laser system assisted for heating has been used to produce the laminate samples to evaluate the importance of the parameters of this technology. Unidirectional thermoplastic prepreg based on polyetheretherketone (PEEK) and carbon fibers has been used for experimental studies. The design of experiments using the Full Factorial Experimental Design (FFED) approach has been employed to investigate the effect of major process parameters on the mechanical properties of the produced laminate samples. The effects of placement rate, laser power, processing temperature, laser placement angle, and compaction pressure of the roller have been evaluated in the samples. It has been found that the processing temperature and the compaction pressure of the roller significantly influence the mechanical strength of the laminate plates. The influence of the laser placement angle is insignificant. The change in processing conditions causes a change in the mechanical characteristics of the laminate plates because of the well-achieved interlaminar bonding between the layers in the laminate. Namely, the samples obtained at the highest investigated processing temperatures and compact roller pressure have the highest values for mechanical strength. The structural morphology of the interface also plays an important role, and because of that, morphological analyses have been made. Microscopic analysis of the samples with the highest values of flexural strength has shown good interlaminar bonding between the layers and a small percentage of pores compared to the samples with the lowest values of flexural strength, where the pore content is higher.
Audience Take Away Notes:
- The audience of this research paper, which includes researchers, engineers, and manufacturers working in the field of composite materials and aerostructures, will be able to use the findings to improve their automated fiber placement processes and optimize the mechanical properties of their composite products. The use of advanced technologies such as AFP with laser heating can help in achieving faster production rates, improved quality, and cost-effectiveness in manufacturing composite parts
- Faculty members could use this research to expand their own studies and teaching in the areas of automated fiber placement, composite materials, and aerostructure manufacturing. The findings of this research can provide valuable insights into the effects of process parameters on the mechanical properties of composite laminates, thus aiding in the development of new techniques and technologies in this field
- The results of this research can also contribute to improving the accuracy and efficiency of designs for composite parts and structures. By understanding how different process parameters impact the mechanical strength and quality of composite laminates, engineers and designers can make informed decisions to optimize their designs and manufacturing processes. This new information can help in solving design problems and achieving better performance in composite materials applications
