CF/LM-PAEK: Characterisation and sensitivity to critical process parameters for automated fibre placement

Raps, Lukas; Chadwick, Ashley; Schiel, Ines; Schmidt, I.

doi:10.1016/j.compstruct.2021.115087

Cited by 15 publications

(19 citation statements)

References 12 publications

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“…Manufacturing equipment-specific processing parameters were optimized in comprehensive Design of Experiment studies and taken up for the following investigation. 6,7 The results were extended in an investigation of layup speed sensitivity of TC1225 and a second CF/LM-PAEK material with 55 % fiber volume fraction. 5 Part 1 of this work investigated in-situ consolidation of 60 % fiber volume fraction (FVF) prepreg tape material, optimized for established production technologies (autoclave and hot press).…”

Section: Intimate Contactmentioning

confidence: 95%

Characteristics of in-situ automated fiber placement carbon-fiber-reinforced low-melt polyaryl ether ketone laminates part 2: Effect of prepreg composition

Raps,

Chadwick,

Mössinger

et al. 2024

Journal of Composite Materials

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This paper presents an investigation into prepreg tape composition and its impact on the consolidation quality of in‐situ Automated Fiber Placement-manufactured laminates. Three different prepreg tape materials were investigated in terms of fiber distribution, porosity and surface roughness. Laminates were manufactured using the in-situ Automated Fiber Placement process and subsequently tested using microanalysis and mechanical testing methods. Higher quality prepreg tape material yielded lower porosity laminates and increased mechanical strength results. The best in-situ Automated Fiber Placement-manufactured laminates achieved 82 % and 88 % of hot-pressed reference tensile- and compressive strength, respectively. Prepreg tape with disadvantageous composition for in‐situ consolidation yielded up to 74 % knockdown compared to the best in-situ consolidated laminates. A five-point bending test was successfully used to determine interlaminar shear strength with significant results relating to consolidation quality. A correlation was successfully established between prepreg composition, resulting laminate consolidation quality and mechanical properties.

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Section: Intimate Contactmentioning

confidence: 95%

Characteristics of in-situ automated fiber placement carbon-fiber-reinforced low-melt polyaryl ether ketone laminates part 2: Effect of prepreg composition

Raps,

Chadwick,

Mössinger

et al. 2024

Journal of Composite Materials

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“…Also, CF/LM-PAEK showed no dependency between layup velocity and bonding strength which was attributed to the low melt viscosity of the matrix. 11 Table 1 provides a summary of all mechanical properties identified by the studies above. This reference shows that process parameters are commonly varied arbitrarily within the settings range of the available layup machine setup.…”

Section: State Of the Artmentioning

confidence: 99%

“…Also, CF/LM-PAEK showed no dependency between layup velocity and bonding strength which was attributed to the low melt viscosity of the matrix. 11…”

Section: State Of the Artmentioning

confidence: 99%

Thermocouple based process optimization for laser assisted automated fiber placement of CF/LM-PAEK

Brandt,

Deden,

Harig

et al. 2023

Journal of Composite Materials

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Self-commitments and increasing legal requirements lead to the compulsion to reduce carbon dioxide emissions in commercial aerospace. One viable approach is the reduction of structural mass, that would reduce emissions for every flight. This is especially true for high cadence singe aisle aircrafts. However, high quantities are required in this segment. To achieve these goals the newly developed low-melt Poly-Aryl-Ether-Ketone (LM-PAEK), a high-performance carbon fiber-reinforced thermoplastic composite was chosen to build a full-scale multi-functional fuselage demonstrator (MFFD) in order to delevelop an automated process that shows these savings. Single-step automated Fiber Placement (AFP) with in-situ consolidation offers distinct advantages in this field with its short curing times and especially by eliminating high amounts of waste otherwise caused by vacuum bagging and related tasks for post-consolidation in an autoclave. In order to ready this technology for future aircraft production this paper demonstrates how the processing window for LM-PAEK tape (TC1225) provided by TORAY was established. By closely linking robot and end-effector data with positionally accurate thermocouple measurements, the determined mechanical properties at coupon level and micro-sections of the manufactured specimens can be precisely correlated. This holistic approach is independent of the placement equipment and may enable global comparability within the community working in the field of thermoplastic AFP. In conclusion the procedure is evaluated and possible simplifications are discussed.

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“…However, the complexity of contact surfaces and the multi‐material characteristics of contact interfaces greatly increase the difficulty of analysis. Typically, investigations into the contact condition and laying quality of AFP predominantly employ variable control methods, and the appropriate parameters can be obtained through abundant experimental data 17–19 . For example, Bakhshi et al 20 systematically studied the influence of roller parameters on laying pressure and quality.…”

Section: Introductionmentioning

confidence: 99%

“…Typically, investigations into the contact condition and laying quality of AFP predominantly employ variable control methods, and the appropriate parameters can be obtained through abundant experimental data. [17][18][19] For example, Bakhshi et al 20 systematically studied the influence of roller parameters on laying pressure and quality. The extensive experimental data offers valuable samples for parameter optimization of fiber placement under comparable circumstances.…”

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confidence: 99%

Modeling of contact mechanics and defects investigation in automated fiber placement

Miao,

Zhu,

Guo

et al. 2024

Polymer Composites

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The layup quality of prepreg fibers onto complex surfaces is the most concerned issue in automated fiber placement (AFP), which is intimately related to the contact stress in tractive rolling contact. An analytical model of tractive rolling contact is proposed in this paper to clarify the defects mechanism during the AFP process, which considers the mold curvatures, mechanical properties of contacted objects, and pose information to make it suitable for irregular surfaces and arbitrary conditions. Classical Hertz theory in this model is expanded to 3D contact area, and multi‐scale deformations are united in the accurate calculation of contact stress under geometric constraints. Based on the model, the phenomena of adhesion, microslip, and the transition between them in AFP are systematically analyzed. For engineering applications, a discrete processing strategy is proposed to quickly obtain the local curvatures of the mold. Additionally, an algorithm is designed to calculate the contact stress of any path. Experimental results on an aircraft component demonstrate the accuracy of the proposed model in restoring the contact stress distribution during AFP. In conjunction with specific layup information, this model exhibits utility in forecasting laying defects and parameter optimization.Highlights An analytical modeling approach based on Hertz theory is proposed to calculate the contact stress in automated fiber placement. A model‐based algorithm is designed and combined with the proposed discrete scheme to quickly restore the contact stress distribution. Contact states related to stress are systematically investigated and defects analysis based on computational mechanics results is illustrated.

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CF/LM-PAEK: Characterisation and sensitivity to critical process parameters for automated fibre placement

Cited by 15 publications

References 12 publications

Characteristics of in-situ automated fiber placement carbon-fiber-reinforced low-melt polyaryl ether ketone laminates part 2: Effect of prepreg composition

Characteristics of in-situ automated fiber placement carbon-fiber-reinforced low-melt polyaryl ether ketone laminates part 2: Effect of prepreg composition

Thermocouple based process optimization for laser assisted automated fiber placement of CF/LM-PAEK

Modeling of contact mechanics and defects investigation in automated fiber placement

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