An inverse model for optimisation of laser heat flux distributions in an automated laser tape placement process for carbon-fibre/PEEK

Stokes-Griffin, Christopher; Compston, Paul

doi:10.1016/j.compositesa.2016.05.034

Cited by 37 publications

(25 citation statements)

References 46 publications

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“…72,73 Many of these tapes/tows had a narrow width of 6.35 mm (0.25 in). 20,27,33,64,66,70,77 –79,94,98,108 Recently, CF/PEEK tapes produced by Suprem are also common, such as AS4/PEEK 9,10,13,16,17,39 –41,126 and IM7/PEEK. 22,23,42,127,128 Furthermore, AS4/PEEK tapes produced by TenCate Advanced Composites were also used.…”

Section: Materials Systemmentioning

confidence: 99%

“…Hence, large homogeneous rectangular spots can be produced by compact optical modules, resulting in uniform, progressive heating across the length and width of the tape which increases the dwell time and therefore the bond quality. 10,13,17,41…”

Section: Heat Sourcesmentioning

confidence: 99%

“…20 Diode lasers were then dominant with several systems having different maximum powers ranging from 600 watt to 6000 watt. 9,13,19,22,23,32,40 –42,47 –53,66,126,128,131,132 A high-power ytterbium fiber laser heat source was being used 20,70 in which a set of optical beam shapers were used to convert the Gaussian profile of the beam into a nearly square top-hat shape. 155 A study on welding with high-power fiber lasers 156 as well as comparison with diode lasers in plastic welding are available.…”

Section: Heat Sourcesmentioning

confidence: 99%

“…They concluded that bonding occurred for consolidation temperatures lower than the melting point provided that the infinite T m was exceeded in the heating phase, hence concluded that the assumption of a bonding temperature threshold of the melting point results in significant underestimation of strength. Stokes-Griffin and Compston 41 proposed a method to determine the required laser heat flux profiles to achieve desired heating zone temperature profiles by means of an inverse thermal model. A step shape temperature profile was shown to achieve the best bonding, whereas a two-stepped heating profile was found to provide a good balance of increased strength with a small increase in power requirement.…”

Section: Atp: Process Versionsmentioning

confidence: 99%

“…10 A closely related process, derived from filament winding, is the tape winding process, which has a low-cost setup without a robotic or gantry-mounted head, and involves a mandrel/tool having a cylindrical shape so that circular rings can be processed. Both flat laminates 9,10,13,16,17,19,21,22,25,30,31,33,35 –69 and circular rings 20,55,70,71 –84 were investigated as well as elliptical rings. 76 Although a promising technique, ATP process still has many challenges to be overcome before it can be ful...…”

Section: Introductionmentioning

confidence: 99%

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Processing of thermoplastic matrix composites through automated fiber placement and tape laying methods

Yassin

Hojjati

2017

Journal of Thermoplastic Composite Materials

106

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Fiber-reinforced composite materials are replacing metallic components due to their higher specific strength and stiffness. Automation and thermoplastics emerged to overcome the time and labor intensive manual techniques and the long curing cycles associated with processing thermoset-based composites. Thermoplastics are processed through fusion bonding which involves applying heat and pressure at the interface. Together with automated techniques (such as automated fiber placement, and automated tape laying), a fast, clean, out-of-autoclave, and automated process can be obtained. A detailed review of thermoplastic composites processing through automated methods is presented. It sheds the light on the materials used and the different heat sources incorporated with the pros and cons of each, with concentration mainly on hot gas torch, laser, and ultrasonic heating. A thorough illustration of the several mechanisms involved in a tow/tape placement process is tackled such as heat transfer, intimate contact development, molecular interdiffusion, void consolidation and growth, thermal degradation, crystallization, and so on. Few gaps and recommendations are included related to materials, laser heat source, heat transfer model, and the use of silicone rubber rollers. A review of optimization studies for tape placement processes is summarized including the main controllable variables and product quality parameters (or responses), with some of the major findings for laser and hot gas torch systems being presented. Both mechanical and physical characterizations are also reviewed including several testing techniques such as short beam shear, double cantilever beam, lap shear, wedge peel, differential scanning calorimetry, and so on. Challenges, however, still exist, such as achieving the autoclave-level mechanical properties and complying with the porosity levels required by the aerospace industry. More work is still necessary to overcome these challenges as well as increase the throughput of the process before it can be totally commercialized.

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