Automated fibre placement based composite structures: Review on the defects, impacts and inspections techniques

Oromiehie, Ebrahim; Prusty, B. Gangadhara; Compston, Paul; Rajan, Ginu

doi:10.1016/j.compstruct.2019.110987

Cited by 152 publications

(70 citation statements)

References 51 publications

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“…The AFP technology is preferably utilised to manufacture complex composite structures (Rudberg et al 2014;Campbell 2004). In the AFP process several narrow pre impregnated material strips, socalled tows, are deposited along a previously programmed path (Oromiehie et al 2019). Therefore, composite material e.g.…”

Section: Manufacturing Processmentioning

confidence: 99%

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Synthetic image data augmentation for fibre layup inspection processes: Techniques to enhance the data set

et al. 2021

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In the aerospace industry, the Automated Fiber Placement process is an established method for producing composite parts. Nowadays the required visual inspection, subsequent to this process, typically takes up to 50% of the total manufacturing time and the inspection quality strongly depends on the inspector. A Deep Learning based classification of manufacturing defects is a possibility to improve the process efficiency and accuracy. However, these techniques require several hundreds or thousands of training data samples. Acquiring this huge amount of data is difficult and time consuming in a real world manufacturing process. Thus, an approach for augmenting a smaller number of defect images for the training of a neural network classifier is presented. Five traditional methods and eight deep learning approaches are theoretically assessed according to the literature. The selected conditional Deep Convolutional Generative Adversarial Network and Geometrical Transformation techniques are investigated in detail, with regard to the diversity and realism of the synthetic images. Between 22 and 166 laser line scan sensor images per defect class from six common fiber placement inspection cases are utilised for tests. The GAN-Train GAN-Test method was applied for the validation. The studies demonstrated that a conditional Deep Convolutional Generative Adversarial Network combined with a previous Geometrical Transformation is well suited to generate a large realistic data set from less than 50 actual input images. The presented network architecture and the associated training weights can serve as a basis for applying the demonstrated approach to other fibre layup inspection images.

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Section: Manufacturing Processmentioning

confidence: 99%

“…Several different defects can result from the fiber placement process. These defects are often directly related to the fibre layup (Oromiehie et al 2019). Harik et al (2018) have investigated the relationship between AFP defects and process planning, layup strategies and processing.…”

Section: Manufacturing Processmentioning

confidence: 99%

Synthetic image data augmentation for fibre layup inspection processes: Techniques to enhance the data set

et al. 2021

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“…Light elements like hydrogen have a high attenuation coefficient and generate strong contrast. DINGO facility at ANSTO operates with a thermal neutron flux of 5.3 × 10 7 n/cm 2 s and 1.15 × 10 7 n/cm 2 s for an L/D of approximately 500 and 1000, respectively. The standard neutron radiography and tomography on DINGO are available with 14–100 µm pixel size.…”

Section: Operational Proceduresmentioning

confidence: 99%

“…With increasing demand for composite components for different applications in aerospace, automotive and marine industries, advanced manufacturing techniques like automated fibre placement (AFP) have been introduced and developed during the last two decades for mass production purposes. 1,2 Along with the automation of manufacturing processes, the need for higher accuracy for producing defect free components also has increased. Consequently, the composite industry has increasingly focused on the use of non-destructive inspection (NDI) techniques for quality control and structural health monitoring over the service life of composite structures.…”

Section: Introductionmentioning

confidence: 99%

Porosity analysis of carbon fibre-reinforced polymer laminates manufactured using automated fibre placement

Oromiehie

Garbe

Prusty

2019

Journal of Composite Materials

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Automated fibre placement-based manufacturing technology is increasingly being used in several engineering applications. Manufacture of carbon fibre-reinforced plastic’s small/large structures have been made possible due to its remarkable capabilities like productivity and accuracy. Nevertheless, making high-quality composite laminate using automated fibre placement relies on the proper selection of critical processing variables to avoid internal flaws during the fibre placement process. Consequently, a reliable non-destructive inspection technique is required for quality assurance and structural integrity of fabricated laminates. Neutron radiography/tomography offers unique imaging capabilities over a wide range of applications including fibre-reinforced polymer composites. The application of this technique towards tomographic reconstruction of automated fibre placement-made thermoplastic composites is presented in this paper. It is shown that the porosity analysis using neutron imaging technique provides reliable information. Additionally, using such technique valuable data regarding the size and the location of the voids in the laminate can be acquired and informed. This will assist the composite structural analysts and designers to select the appropriate processing parameters towards a defect free automated fibre placement part manufacture.

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“…Composite materials have been widely used in engineering applications given their high specific intensity and specific rigidity [1][2][3][4][5][6]. Composite prepreg tape winding-a process utilized to fabricate revolving body composite structures-is recognized as an effective method for producing aerospace products, such as solid rocket motor nozzles, satellite fairings and missile noses [7][8][9].…”

Section: Introductionmentioning

confidence: 99%

Influence Mechanism and Optimization Analysis of Technological Parameters for the Composite Prepreg Tape Winding Process

Deng

Shi

2020

Polymers

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Composite prepreg tape winding technology has proven to be an effective method for manufacturing revolving body composite structures in aerospace field. Process parameters including heating temperature, tape tension and roller pressure have an important impact on the winding products’ mechanical property such as tensile strength. The aim of this study is to investigate the influence mechanism and optimization analysis of parameters for the composite prepreg tape winding process. Firstly, the sensitivity analysis for single parameter had be employed to reveal the influence mechanism of each winding parameter change on tensile strength. Secondly, iso-surfaces analysis for parameter range had be applied to describe the distribution law of parameter with continuous distribution characteristics. Then the coupling analysis for process parameters was carried out employing response surface methodology. The analysis results showed that tape tension has the most significant effect on the winding products’ tensile strength. And the outstanding parameter combination with the heating temperature of 72 °C, tape tension of 307 N and roller pressure of 1263 N was provided by response surface design software via desirability function method. The validation experiments showed that the optimal parameter combination has a positive guiding significance for improving the quality of winding products.

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Automated fibre placement based composite structures: Review on the defects, impacts and inspections techniques

Cited by 152 publications

References 51 publications

Synthetic image data augmentation for fibre layup inspection processes: Techniques to enhance the data set

Synthetic image data augmentation for fibre layup inspection processes: Techniques to enhance the data set

Porosity analysis of carbon fibre-reinforced polymer laminates manufactured using automated fibre placement

Influence Mechanism and Optimization Analysis of Technological Parameters for the Composite Prepreg Tape Winding Process

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