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

2019 ◽  
Vol 3 (2) ◽  
pp. 56 ◽  
Author(s):  
Falk Heinecke ◽  
Christian Willberg
Keyword(s):  
Composite Structures ◽  
Review Paper ◽  
State Of The Art ◽  
Fiber Composite ◽  
Research Gaps ◽  
Manufacturing Defects ◽  
Cycle Times ◽  
Fiber Placement ◽  
Simulation Based ◽  
Automated Fiber Placement

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.

Induced defect layer method to characterize the effect of fiber tow gaps for the laminates manufactured by automated fiber placement technique

2021 ◽  
pp. 002199832110316
Author(s):  
Mohammadhossein Ghayour ◽  
Mehdi Hojjati ◽  
Rajamohan Ganesan
Keyword(s):  
Composite Laminates ◽  
Composite Structures ◽  
Structural Integrity ◽  
Mechanical Response ◽  
Defect Layer ◽  
Damage Analysis ◽  
Manufacturing Defects ◽  
Fiber Placement ◽  
Layer Method ◽  
Automated Fiber Placement

Automated manufacturing defects are new types of composite structure defects induced during fiber deposition by robots. Fiber tow gap is one of the most probable types of defects observed in the Automated Fiber Placement (AFP) technique. This defect can affect the structural integrity of structures by reducing structural strength and stiffness. The effect of this defect on the mechanical response of the composite laminates has been investigated experimentally in the literature. However, there is still no efficient numerical/analytical method for damage assessment of composite structures with distributed induced gaps manufactured by the AFP technique. The present paper aims to develop the Induced Defect Layer Method (IDLM), a new robust meso-macro model for damage analysis of the composite laminates with gaps. In this method, a geometrical parameter, Gap Percentage (GP), is implemented to incorporate the effect of induced-gaps in the elastic, inelastic, and softening behavior at the material points. Thus, while the plasticity and failure of the resin pockets in conjunction with intralaminar composite damages can be evaluated by this method, the defective areas are not required to be defined as resin elements in the Finite Element (FE) models. It can also be applied for any arbitrary distributions of the defects in the multi-layer composite structures, making it a powerful tool for continuum damage analysis of large composite structures. Results indicate that the proposed method can consider the effect of gaps in both elastic and inelastic behavior of the composite laminate with defects. It also provides good agreement with the experimental results.

scholarly journals A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

2018 ◽  
Vol 2 (3) ◽  
pp. 42 ◽  
Author(s):  
Mohammad Rakhshbahar ◽  
Michael Sinapius
Keyword(s):  
Mechanical Properties ◽  
Composite Structures ◽  
Fiber Composite ◽  
Gap Effect ◽  
Fiber Placement ◽  
Reinforced Plastics ◽  
Novel Approach ◽  
Automated Fiber Placement ◽  
Automated Processing ◽  
Processing Techniques

Automated processing techniques such as automated fiber placement (AFP) or automated tape laying (ATL) are well known nowadays. However, there is still a lot of potential for these methods to achieve better results, especially for large and complex composite structures. In this experimental work, the gap effect with the Automated Fiber Placement is shown and a solution to overcome this drawback is presented. The gaps are particularly apparent on complex and/or double-curved surfaces and reduce the mechanical properties of the composite structure. In order to cover the unavoidable weak area of this effect, a plurality of fiber composite layers are laid on top of one another in order to increase the mechanical properties of components. This in turn makes the components heavier and more expensive to produce. In this new method, the gaps are detected by profile sensor after placement of the tape on the mold. The gaps are filled with the aid of a 3D printer with carbon continuous-fiber reinforced plastics. By combining the 3D printing and AFP technology, composite parts can be manufactured in a more homogeneous manner. Subsequently, the components are produced faster, cheaper and even lighter because of the avoidance of the additional layers.

Study of integral hat-stiffened composite structures manufactured by automated fiber placement and co-curing process

2020 ◽  
Vol 246 ◽  
pp. 112427
Author(s):  
Cong Zhao ◽  
Xianfeng Wang ◽  
Xingyu Liu ◽  
Cheng Ma ◽  
Qiyi Chu ◽  
...  
Keyword(s):  
Composite Structures ◽  
Curing Process ◽  
Fiber Placement ◽  
Automated Fiber Placement

scholarly journals Defect Characteristics and Online Detection Techniques During Manufacturing of FRPs Using Automated Fiber Placement: A Review

Polymers ◽  
2020 ◽  
Vol 12 (6) ◽  
pp. 1337 ◽  
Author(s):  
Shouzheng Sun ◽  
Zhenyu Han ◽  
Hongya Fu ◽  
Hongyu Jin ◽  
Jaspreet Singh Dhupia ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Large Scale ◽  
Variable Stiffness ◽  
Future Research ◽  
Online Detection ◽  
Manufacturing Defects ◽  
Manufacturing Method ◽  
Detection Techniques ◽  
Fiber Placement ◽  
Automated Fiber Placement

Automated fiber placement (AFP) is an advanced manufacturing method for composites, which is especially suitable for large-scale composite components. However, some manufacturing defects inevitably appear in the AFP process, which can affect the mechanical properties of composites. This work aims to investigate the recent works on manufacturing defects and their online detection techniques during the AFP process. The main content focuses on the position defect in conventional and variable stiffness laminates, the relationship between the defects and the mechanical properties, defect control methods, the modeling method for a void defect, and online detection techniques. Following that, the contributions and limitations of the current studies are discussed. Finally, the prospects of future research concerning theoretical and practical engineering applications are pointed out.

Corrigendum to “Effect of automated fiber placement (AFP) manufacturing signature on mechanical performance of composite structures” [Compos. Struct. 228 (2019) 111335]

2020 ◽  
Vol 233 ◽  
pp. 111700
Author(s):  
Minh Hoang Nguyen ◽  
Avinkrishnan A. Vijayachandran ◽  
Paul Davidson ◽  
Damon Call ◽  
Dongyeon Lee ◽  
...  
Keyword(s):  
Composite Structures ◽  
Mechanical Performance ◽  
Fiber Placement ◽  
Automated Fiber Placement

scholarly journals Multiscale Collaborative Optimization of Processing Parameters for Carbon Fiber/Epoxy Laminates Fabricated by High-Speed Automated Fiber Placement

2016 ◽  
Vol 2016 ◽  
pp. 1-14 ◽  
Author(s):  
Zhenyu Han ◽  
Shouzheng Sun ◽  
Zhongxi Shao ◽  
Hongya Fu
Keyword(s):  
Mechanical Properties ◽  
Strain Energy ◽  
High Speed ◽  
Processing Parameters ◽  
Collaborative Optimization ◽  
Manufacturing Defects ◽  
Fiber Placement ◽  
Automated Fiber Placement ◽  
Processing Optimization ◽  
Carbon Fiber Epoxy

Processing optimization is an important means to inhibit manufacturing defects efficiently. However, processing optimization used by experiments or macroscopic theories in high-speed automated fiber placement (AFP) suffers from some restrictions, because multiscale effect of laying tows and their manufacturing defects could not be considered. In this paper, processing parameters, including compaction force, laying speed, and preheating temperature, are optimized by multiscale collaborative optimization in AFP process. Firstly, rational model between cracks and strain energy is revealed in order that the formative possibility of cracks could be assessed by using strain energy or its density. Following that, an antisequential hierarchical multiscale collaborative optimization method is presented to resolve multiscale effect of structure and mechanical properties for laying tows or cracks in high-speed automated fiber placement process. According to the above method and taking carbon fiber/epoxy tow as an example, multiscale mechanical properties of laying tow under different processing parameters are investigated through simulation, which includes recoverable strain energy (ALLSE) of macroscale, strain energy density (SED) of mesoscale, and interface absorbability and matrix fluidity of microscale. Finally, response surface method (RSM) is used to optimize the processing parameters. Two groups of processing parameters, which have higher desirability, are obtained to achieve the purpose of multiscale collaborative optimization.

scholarly journals Bonding between high-performance polymer processed by Fused Filament Fabrication and PEEK/carbon fiber laminate

2021 ◽  
Author(s):  
Isciane Caprais ◽  
Pierre Joyot ◽  
Emmanuel Duc ◽  
Simon Deseur
Keyword(s):  
Additive Manufacturing ◽  
Composite Structures ◽  
Composite Laminate ◽  
High Performance ◽  
Processing Conditions ◽  
Fused Filament Fabrication ◽  
Fiber Placement ◽  
High Performance Polymer ◽  
Automated Fiber Placement ◽  
The Impact

Automated fiber placement processes could be combined with additive manufacturing to produce more functionally complex composite structures with more flexibility. The challenge is to add functions or reinforcements to PEEK/carbon composite parts manufactured by automated fiber placement process, with additive manufacturing by fused filament fabrication. This consists of extruding a molten polymer through a nozzle to create a 3D part. Bonding between polymer filaments is a thermally driven phenomenon and determines the integrity and the final mechanical strength of the printed part. 3d-printing high performance polymers is still very challenging because they involve high thermal gradients during the process. The purpose of this work is to find a process window where the bonding strength is maximized between the composite laminate and the first layer of printed polymer, and inside the printed function as well. Experimental measurements of the temperature profiles at the interface between a composite substrate and 3d-printed PEI under different processing conditions were carried out. The interface was observed using microscopic sections. The methodology for studying the impact of printing parameters on the cohesion and adhesion of printed parts with a composite laminate is described. This work provides insights about the influence of processing conditions on the bond formation between high-performance polymer surfaces. It highlights the importance of controlling the thermal history of the materials all along the process.

Effect of automated fiber placement (AFP) manufacturing signature on mechanical performance of composite structures

2019 ◽  
Vol 228 ◽  
pp. 111335 ◽  
Author(s):  
Minh Hoang Nguyen ◽  
Avinkrishnan A. Vijayachandran ◽  
Paul Davidson ◽  
Damon Call ◽  
Dongyeon Lee ◽  
...  
Keyword(s):  
Composite Structures ◽  
Mechanical Performance ◽  
Fiber Placement ◽  
Automated Fiber Placement

Characterization of process-induced defects in automated fiber placement manufacturing of composites using fiber Bragg grating sensors

2017 ◽  
Vol 17 (1) ◽  
pp. 108-117 ◽  
Author(s):  
Ebrahim Oromiehie ◽  
B Gangadhara Prusty ◽  
Paul Compston ◽  
Ginu Rajan
Keyword(s):  
Fiber Bragg Grating ◽  
Structural Integrity ◽  
Bragg Grating ◽  
Inspection Method ◽  
Manufacturing Defects ◽  
Fiber Placement ◽  
Fiber Bragg Grating Sensors ◽  
Placement Method ◽  
Automated Fiber Placement ◽  
On Line

With the increasing use of automated fiber placement method for manufacturing highly precise bespoke composite components in the aerospace industry, the level of manufacturing defects within the laminate structure needs to be monitored and minimized for structural integrity. One of the main common defects in automated fiber placement process is misalignment between the tape paths in successive courses which leads to non-integrity of laminate and consequently significant reduction in mechanical strength of the laminate. Therefore, it is necessary to find an appropriate inspection method to monitor and identify these processing defects at the earlier stages of manufacturing. Since optical fiber Bragg grating sensors are being increasingly utilized for structural health monitoring in composite materials and as they were successfully implemented by Oromiehie et al. in their earlier work for on-line lay-up process monitoring, the same methodology is once again tried for identifying the misalignment defects in automated fiber placement process. The experiments are carried out on glass-fiber/nylon laminate with embedded fiber Bragg gratings for the automated tape placement method. The defects due to misalignment are identified by the fiber Bragg grating sensors through their reflected wavelength changes during the automated manufacturing process. The analysis of results indicates that the fiber Bragg grating sensors can be reliably implemented for on-line defect monitoring during the automated fiber placement process to ensure the quality of final product and maintain the expected design life.

scholarly journals Influence of Embedded Gap and Overlap Fiber Placement Defects on Interlaminar Properties of High Performance Composites

Materials ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5332
Author(s):  
Denis Cartié ◽  
Marine Lan ◽  
Peter Davies ◽  
Christophe Baley
Keyword(s):  
High Performance ◽  
Crack Arrest ◽  
Shear Loading ◽  
Plane Shear ◽  
Manufacturing Defects ◽  
Fiber Placement ◽  
Out Of Plane ◽  
Beam Shear ◽  
Automated Fiber Placement ◽  
Interlaminar Shear

Automated fiber placement (AFP), once limited to aerospace, is gaining acceptance and offers great potential for marine structures. This paper describes the influence of manufacturing defects, gaps, and overlaps, on the out-of-plane properties of carbon/epoxy composites manufactured by AFP. Apparent interlaminar shear strength measured by short beam shear tests was not affected by the presence of defects. However, the defects do affect delamination propagation. Under Mode I (tension) loading a small crack arrest effect is noted, resulting in higher apparent fracture energies, particularly for specimens manufactured using a caul plate. Under Mode II (in-plane shear) loading there is a more significant effect with increased fracture resistance, as stable propagation for specimens with small gaps changes to arrest with unstable propagation for larger gaps.

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