Models were developed which simulate the processing of thermoplastic matrix composites. The models relate the applied temperature, pressure, speed, and time to the temperature, crystallinity, consolidation, interlaminar bonding, and residual stresses and strains inside the composite. The formulations follow the models proposed by Springer, Loos, and their coworkers for manufacturing plates in a press or in an autoclave, but were extended to include cylindrical geometries, variations in the applied temperatures and pressures with position and time, and rapid bonding. These extensions make the models applicable to the manufacture of plates by tape laying and to filament winding of cylinders. These models were incorporated into a user friendly computer code which can be used to generate numerical results and to select the appropriate processing conditions for processing thermoplastic composite plates 1) in an autoclave, 2) in a press, or 3) by tape laying, and 4) for filament winding thermoplastic composite cylinders.

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Tests were conducted to validate the thermoplastic manufacturing process models described by Mantell and Springer. In the tests, APC-2 graphite/PEEK plates were fabricated both in a press and with a specially constructed tape laying apparatus. The tem perature, intimate contact and bonding inside the plates were measured. The data agreed well with the results of the model.

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