In Situ Thermal Nondestructive Evaluation for Assessing Part Quality During Composite Automated Fiber Placement

2018 ◽  
Vol 1 (4) ◽  
Author(s):  
Elizabeth Gregory ◽  
Peter Juarez
Keyword(s):  
Nondestructive Evaluation ◽  
Composite Fiber ◽  
Cylindrical Part ◽  
Defect Characterization ◽  
Data Sets ◽  
Fiber Placement ◽  
Part Quality ◽  
Automated Fiber Placement

This paper presents data from an innovative nondestructive evaluation (NDE) method for automated composite fiber placement fabrication. Using Infrared images of the fiber, as it was being placed, we are able to provide valuable information about the quality of the part during fabrication. Herein, we discuss the methodology for data collection and processing. The described in situ thermal NDE process is found to be applicable for identifying fiber tow overlaps, gaps, twists, puckering, and poor ply adhesion prior to cure, thereby reducing the time and cost associated with post cure flaw repair or scrapping parts. This paper also describes the process of assembling data sets for an entire part beyond simple frame by frame analysis. Example data sets for both a flat part and a larger cylindrical part are presented to demonstrate the type of defect characterization information that can be obtained.

scholarly journals Review: Filament Winding and Automated Fiber Placement with In Situ Consolidation for Fiber Reinforced Thermoplastic Polymer Composites

Polymers ◽  
2021 ◽  
Vol 13 (12) ◽  
pp. 1951
Author(s):  
Yi Di Boon ◽  
Sunil Chandrakant Joshi ◽  
Somen Kumar Bhudolia
Keyword(s):  
Processing Parameters ◽  
Filament Winding ◽  
Reference Points ◽  
Thermoplastic Composites ◽  
Manufacturing Processes ◽  
Fiber Reinforced ◽  
Consolidation Process ◽  
Fiber Placement ◽  
Automated Fiber Placement

Fiber reinforced thermoplastic composites are gaining popularity in many industries due to their short consolidation cycles, among other advantages over thermoset-based composites. Computer aided manufacturing processes, such as filament winding and automated fiber placement, have been used conventionally for thermoset-based composites. The automated processes can be adapted to include in situ consolidation for the fabrication of thermoplastic-based composites. In this paper, a detailed literature review on the factors affecting the in situ consolidation process is presented. The models used to study the various aspects of the in situ consolidation process are discussed. The processing parameters that gave good consolidation results in past studies are compiled and highlighted. The parameters can be used as reference points for future studies to further improve the automated manufacturing processes.

scholarly journals Automated fabrication of hybrid thermoplastic prepreg material to be processed by In-Situ Consolidation Automated Fiber Placement process

2018 ◽  
Vol 188 ◽  
pp. 01024
Author(s):  
Vincenzo Iannone ◽  
Marco Barile ◽  
Leonardo Lecce
Keyword(s):  
Carbon Fiber ◽  
Hot Forming ◽  
Framework Programme ◽  
Thermal Cycles ◽  
Forming Process ◽  
High Performing ◽  
Fiber Placement ◽  
Research And Innovation ◽  
Automated Fiber Placement

This work deals with the fabrication of an innovative hybrid thermoplastic prepreg by continuous hot forming process. The material, suitable also for Automated Fiber Placement process, is produced through a consolidation of commercial PEEK-Carbon Fiber prepreg sandwiched between two amorphous PEI films. Consolidation is performed by a purpose-designed automated prototype equipment operating on defined pressure and thermal cycles. Then preliminary tests on first trials produced were carried out. These activities have been developed in the frame of the NHYTE project, a Research and Innovation Action funded by the European Union's H2020 framework programme, under Grant Agreement No 723309 NOVOTECH acting as Coordinator presents this paper on behalf of all Partners of the project. The proof of NHYTE project concept is the manufacturing of a fastener free and high performing fuselage portion demonstrator.

scholarly journals In Situ Joining of Unidirectional Tapes on Long Fiber Reinforced Thermoplastic Structures by Thermoplastic Automated Fiber Placement for Scientific Sounding Rocket Applications

Procedia CIRP ◽  
2019 ◽  
Vol 85 ◽  
pp. 189-194
Author(s):  
Ralf Engelhardt ◽  
Stefan Ehard ◽  
Tobias Wolf ◽  
Jonathan Oelhafen ◽  
Andreas Kollmannsberger ◽  
...  
Keyword(s):  
Sounding Rocket ◽  
Fiber Reinforced ◽  
Fiber Placement ◽  
Automated Fiber Placement

Impact of layup rate on the quality of fiber steering/cut-restart in automated fiber placement processes

2015 ◽  
Vol 22 (2) ◽  
pp. 165-173 ◽  
Author(s):  
Jihua Chen ◽  
Teresa Chen-Keat ◽  
Mehdi Hojjati ◽  
AJ Vallee ◽  
Marc-Andre Octeau ◽  
...  
Keyword(s):  
Compaction Pressure ◽  
Experimental Studies ◽  
Process Condition ◽  
Processing Parameters ◽  
Experimental Results ◽  
High Quality ◽  
Fiber Placement ◽  
Automated Fiber Placement

AbstractDeveloping reliable processes is one of the key elements in producing high-quality composite components using an automated fiber placement (AFP) process. In this study, both simulation and experimental studies were carried out to investigate fiber steering and cut/restart under different processing parameters, such as layup rate and compaction pressure, during the AFP process. First, fiber paths were designed using curved fiber axes with different radii. Fiber placement trials were then conducted to investigate the quality of the steered fiber paths. Furthermore, a series of sinusoidal fiber paths were fiber placed and investigated. Moreover, a six-ply laminate with cut-outs in it was manufactured in the cut/restart trials. The accuracy of the fiber cut/restart was compared at different layup rates for both one- and bi-directional layups. Experimental results show that it was possible to layup steered fiber paths with small radii of curvature (minimum 114 mm) designed for this study when the proper process condition was used. It was observed from the cut/restart trials that the quality of tow cut was independent of layup speed; however, the accuracy of tow restart was related to the layup speed. The faster the layup speed, the less accurate was the tow restart.

scholarly journals Advances in in situ inspection of automated fiber placement systems

2016 ◽  
Author(s):  
Peter D. Juarez ◽  
K. Elliott Cramer ◽  
Jeffrey P. Seebo
Keyword(s):  
Fiber Placement ◽  
Automated Fiber Placement

Online Prediction and Verification of Cured Quality of Advanced Composites in Autoclave Process

2016 ◽  
Vol 703 ◽  
pp. 3-10
Author(s):  
Yong An Zhang ◽  
Li Hua Zhan
Keyword(s):  
In Situ Monitoring ◽  
Metallographic Analysis ◽  
Resin Flow ◽  
Composite Part ◽  
Monitoring Method ◽  
Verification Method ◽  
Part Quality ◽  
Ultrasonic Phased Array

The strain in curing process of composite part would be influenced by curing compaction, resin flow, curing action and tool-part interaction, meanwhile these factors would also influence the final cured quality of composite part. In this paper, FBG(fiber Bragg grating) sensors are used to in-situ monitoring the strain of composite parts, which are cured in four different pressure situation by autoclave: 0.0Mpa,0.2Mpa,0.4Mpa,0.6MPa. by analyzing the strain change rule, the part quality is predicted, then the predictive result is compared with some verification method: measurement of part’s boundary dimension, ultrasonic phased array scanning, metallographic analysis. The result shows that, the prediction is consistent with verification, the in-situ monitoring method by using FBG sensor is available for predicting cured quality of composite parts accurately: increase curing pressure is benefit of part compaction, resin flow, and reduce delamination,pores in composite part, finally improving the part quality dramatically.

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