Title: In-Situ Consolidation of Complex Curvature Thermoplastic Composite Part Manufactured by Automated Fiber Placement

Authors: Dan Ursenbach, Justin Merotte and Noushin Bahramshahi

DOI: 10.33599/nasampe/s.20.0201

Abstract: This paper presents a project at Collins Aerospace on the manufacturing of complex curvature thermoplastic composite parts with laser assisted fiber placement (LAFP) in-situ consolidation. To date, most of the work done in in-situ consolidated thermoplastic AFP parts have been limited to simple curvature parts, or body of revolution parts where the AFP process has been used much like a Filament Winding process. This work investigates the processing of a complex 3D part with double curvature surface and confined space constraints via LAFP in-situ consolidation. A true 3D complex curvature part inevitably contains fiber convergence zones, and the gaps associated with such zones. These gaps present a significant challenge to achieving good laminate properties, and a subsequent design optimization was performed to minimize them. Other challenges characteristic of in-situ and thermoplastic processing included print-through of tool release film and splices, which require industry solutions. Finally, a set of validation articles were fabricated by applying the appropriate processing settings. While the finished validation articles had limited defect areas, they were deemed acceptable for postlamination operations like bonding or induction welding of thermoplastic stiffeners.

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Conference: SAMPE 2020 | Virtual Series

Publication Date: 2020/06/01

SKU: TP20-0000000201

Pages: 12

Price: FREE