Avoiding defects in manufacturing processes: A review for automated CFRP production

Perner, Marcus; Algermissen, Stephan; Keimer, Ralf; Monner, Hans Peter

doi:10.1016/j.rcim.2015.10.008

Cited by 46 publications

(22 citation statements)

References 51 publications

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“…It corresponds to a multiple of a tow width. The controlled deposition of fibers on complex geometries, even using fiber steering is challenging for following reasons [28,29]:…”

Section: Manufacturing Induced Imperfectionsmentioning

confidence: 99%

“…Figure 6) are primarily due to the kinematic characteristics of the AFP machine and its control [16,31]. Perner et al [29] argue that process speed and inertia effects of the robot under load affect the positioning accuracy of the end effector. Further influencing factors for the occurrence of fiber tow misalignments are the processability of the fiber material and the complexity of the layup [27,41].…”

Section: Type Ii-tow Misalignmentmentioning

confidence: 99%

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Manufacturing-Induced Imperfections in Composite Parts Manufactured via Automated Fiber Placement

Heinecke

Willberg

2019

J. Compos. Sci.

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The automated fiber placement process (AFP) enables the manufacturing of large and geometrical complex fiber composite structures with high quality at low cycle times. Although the AFP process is highly accurate and reproducible, manufacturing induced imperfections in the produced composite structure occur. This review summarizes and classifies typical AFP-related manufacturing defects. Several methodologies for evaluating the effects of such manufacturing defects from the literature are reviewed. This review paper presents recent scientific contributions and discusses proposed experimental and simulation-based methodologies. Among the identified ten defect classes, gaps and overlaps are predominant. This paper focuses then on methods for modelling and assessing gaps and overlaps. The state of the art in modelling gaps and overlaps and assessing their influence on mechanical properties is presented. Finally, research gaps and remaining issues are identified.

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“…It corresponds to a multiple of a tow width. The controlled deposition of fibers on complex geometries, even using fiber steering is challenging for following reasons [28,29]:…”

Section: Manufacturing Induced Imperfectionsmentioning

confidence: 99%

Section: Type Ii-tow Misalignmentmentioning

confidence: 99%

Manufacturing-Induced Imperfections in Composite Parts Manufactured via Automated Fiber Placement

Heinecke

Willberg

2019

J. Compos. Sci.

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“…In the literature, the damage behavior of composite materials has been widely investigated, pointing out the effects in terms of induced damage of impacts with foreign objects [9][10][11][12][13][14], of the manufacturing or the assembly processes [15][16][17][18] and, finally, the effects of service loading conditions.…”

Section: Introductionmentioning

confidence: 99%

Numerical-Experimental Investigation into the Tensile Behavior of a Hybrid Metallic–CFRP Stiffened Aeronautical Panel

et al. 2020

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In this work, the tensile behavior of a hybrid metallic–composite stiffened panel is investigated. The analyzed structure consists of an omega-reinforced composite fiber-reinforced plastic (CFRP) panel joined with a Z-reinforced aluminum plate by fasteners. The introduced numerical model, able to simulate geometrical and material non-linearities, has been preliminary validated by means of comparisons with experimental test results, in terms of strain distributions in both composite and metallic sub-components. Subsequently, the inter-laminar damage behavior of the investigated hybrid structure has been studied numerically by assessing the influence of key structural subcomponents on the damage evolution of an artificial initial debonding between the composite skin and stringers.

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“…To improve the production rate and to reduce the production cost, automated manufacturing of FMLs represents a significant goal for future applications in the aerospace field. One possible solution is to use automated tape laying process (ATP) for pre-preg roll in conjunction with picking-andplacing for the aluminium sheets [7,8].…”

Section: Introductionmentioning

confidence: 99%

Non-destructive testing investigation of gaps in thin Glare laminates

Jakubczak

Nardi

Bieniaś

et al. 2019

Nondestructive Testing and Evaluation

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The manufacturing procedure of Fibre Metal Laminates (FMLs), such as Glare, consisting of alternating layers of pre-preg fibre and metal sheets is relatively complex, and defects can be introduced during manufacturing. The automation of the manufacturing steps is vital for future Glare production, and specific defects have to be considered. Among them, gaps between pre-preg plies represent a potential risk for the mechanical performances of the final laminate. In this paper/research, non-destructive testing (NDT) based on ultrasonic inspections are performed on Glare laminates with pre-preg gaps in order to extend and improve the current state of the art to different pre-preg gap widths, depths, and specimen lay-ups. Firstly, gaps were introduced in Glare specimens. Then, a conventional C-scan ultrasonic inspection is performed. In order to overcome the current limitations of a top or planar view of the laminates, the evaluation of the depth of the gaps in the laminates is performed by means of phased array pulse-echo ultrasonic testing (PAUT). Lastly, images of the laminate cross-section cut-outs have been collected in order to provide a meaningful evidence of the ultrasonic-based analysis. Results from different Glare lay-ups and gap widths and depths show the accuracy of the proposed investigation which is able to provide a detailed assessment of the gap occurrences also for very thin laminates, paving the way for portable and faster quality control strategies for future automated Glare manufacturing.

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Avoiding defects in manufacturing processes: A review for automated CFRP production

Cited by 46 publications

References 51 publications

Manufacturing-Induced Imperfections in Composite Parts Manufactured via Automated Fiber Placement

Manufacturing-Induced Imperfections in Composite Parts Manufactured via Automated Fiber Placement

Numerical-Experimental Investigation into the Tensile Behavior of a Hybrid Metallic–CFRP Stiffened Aeronautical Panel

Non-destructive testing investigation of gaps in thin Glare laminates

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