Title: Automated Induction Welding of Large Thermoplastic Composite Structure

Authors: Wenping Zhao, Justin Alms, Brigid Blakeslee, Abhijit Chakraborty, John Gangloff, Mike Klecka, Jeff Mendoza, Zhigang Wang, Lei Xing

DOI: 10.33599/nasampe/s.22.0867

Abstract: Lightweight carbon fiber reinforced thermoplastic composites (CF-TPCs) are internationally recognized as materials capable of meeting the future aerospace market rate demands with potential recyclability. One key contributor to the rapid manufacturing rate of the CF-TPC is its weldability that allows the reduction or even elimination of time-consuming adhesive bonding and or mechanical fastening. Induction is a rapid heating method for welding of unidirectional tape or fabric based CF-TPC parts. However, to date, there are no mature solutions available for large, curved, varying thickness parts such as engine nacelle fan cowls and aircraft fuselage panels/barrels. The objective of this work is to develop a robotic cell that is capable of automatically navigating along the weld-line of a large composite part with in-situ sensing and control to significantly reduce the part specific induction welding (IW) process implementation. Robotic automation is required for safe, reliable, and efficient IW of large CF-TPC components in production-level environments. Technologies developed in this work include robotic IW cell configuration, end effector design, tool path planning, sensing, in-situ control, and the human machine interface (HMI). This development culminated with a demonstration of IW a simplified skin-stiffened aircraft component.

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Conference: SAMPE 2022

Publication Date: 2022/05/23

SKU: TP22-0000000867

Pages: 16

Price: $32.00