Title: Real-Time Material Certification of Composites Using a Digital Twin

Authors: Tiffany A. Stewart, David W. Shahan, Yuksel C. Yabansu

DOI: 10.33599/nasampe/s.24.0136

Abstract: Qualification of manufacturing lines for new materials requires expensive and labor intensive approaches. These approaches lead to a substantial amount of qualification time and testing required for introduction of new materials and optimized processes to industry. Digital twins in material processing can address the shortcomings of traditional approaches by providing real-time tracking and prediction of material properties, improved process efficiency, and predictive maintenance capabilities. In this study, we demonstrate the ability to perform real time composite material certification using a digital twin on a research-scale prepreg line coupled with online sensing and physics-informed models. Specifically, machine learning algorithms based on Bayesian methods and Kalman filters fed by online sensor data will be demonstrated for prediction and tracking of material key characteristics.

References: 1.Zheng, Hao, Wenjian Zhang, Bowen Li, Junjie Zhu, Chaohang Wang, Guojun Song, Guangshun Wu, Xiaoping Yang, Yudong Huang, and Lichun Ma. ""Recent advances of interphases in carbon fiber-reinforced polymer composites: A review."" Composites Part B: Engineering 233 (2022): 109639. 2.Irving, Philip E., and Costas Soutis, eds. Polymer composites in the aerospace industry. Woodhead Publishing, 2019. 3.van Grootel, Alexander, Jiyoun Chang, Brian L. Wardle, and Elsa Olivetti. ""Manufacturing variability drives significant environmental and economic impact: the case of carbon fiber reinforced polymer composites in the aerospace industry."" Journal of Cleaner Production 261 (2020): 121087. 4.Timmis, Andrew J., Alma Hodzic, Lenny Koh, Michael Bonner, Constantinos Soutis, Andreas W. Schäfer, and Lynnette Dray. ""Environmental impact assessment of aviation emission reduction through the implementation of composite materials."" The International Journal of Life Cycle Assessment 20 (2015): 233-243. 5.Tanabe, D., K. Nishiyabu, and T. Kurashiki. ""Effects of processing conditions in unidirectional carbon fiber thermoplastic tape laying."" In 20th International Conference on Composite Materials, Copenhagen, 19–24 July 2015. 2015. 6.Rimmel, Oliver, David May, Christian Goergen, Artur Poeppel, and Peter Mitschang. ""Development and validation of recycled carbon fiber-based binder tapes for automated tape laying processes."" Journal of Composite Materials 53, no. 23 (2019): 3257-3268. 7.Yassin, Khaled, and Mehdi Hojjati. ""Processing of thermoplastic matrix composites through automated fiber placement and tape laying methods: A review."" Journal of Thermoplastic Composite Materials 31, no. 12 (2018): 1676-1725. 8.Andreozzi, Marina, Iacopo Bianchi, Serena Gentili, Tommaso Mancia, and Michela Simoncini. ""Effect of Fabric Areal Weight on the Mechanical Properties of Composite Laminates in Carbon-Fiber-Reinforced Polymers."" Journal of Composites Science 7, no. 9 (2023): 351. 9.Ahn, K. J., and James C. Seferis. ""Prepreg processing science and engineering."" Polymer Engineering & Science 33, no. 18 (1993): 1177-1188. 10.Galos, Joel. ""Thin-ply composite laminates: a review."" Composite Structures 236 (2020): 111920. 11.Grieves, Michael, and John Vickers. ""Digital twin: Mitigating unpredictable, undesirable emergent behavior in complex systems."" Transdisciplinary perspectives on complex systems: New findings and approaches (2017): 85-113. 12.Grieves, Michael. ""Digital twin: manufacturing excellence through virtual factory replication."" White paper 1, no. 2014 (2014): 1-7. 13.Jones, David, Chris Snider, Aydin Nassehi, Jason Yon, and Ben Hicks. ""Characterising the Digital Twin: A systematic literature review."" CIRP journal of manufacturing science and technology 29 (2020): 36-52. 14.Hou, Jiatong, Bo You, Jiazhong Xu, and Tao Wang. ""Prediction of curing process for thermosetting prepreg compression molding process based on machine learning."" Polymer Composites 43, no. 3 (2022): 1749-1762. 15.Schmidt, Carsten, Tristan Hocke, and Berend Denkena. ""Artificial intelligence for non-destructive testing of CFRP prepreg materials."" Production Engineering 13 (2019): 617-626. 16.Gangloff Jr, John J., Pavel Simacek, Shatil Sinha, and Suresh G. Advani. ""A process model for the compaction and saturation of partially impregnated thermoset prepreg tapes."" Composites Part A: Applied Science and Manufacturing 64 (2014): 234-244. 17.Hubert, Pascal, and Anoush Poursartip. ""A method for the direct measurement of the fibre bed compaction curve of composite prepregs."" Composites part A: applied science and manufacturing 32, no. 2 (2001): 179-187. 18.Sorba, G., C. Binetruy, E. Syerko, A. Leygue, S. Comas-Cardona, JP-H. Belnoue, O. J. Nixon-Pearson, D. S. Ivanov, S. R. Hallett, and S. G. Advani. ""Multi-scale modelling of non-uniform consolidation of uncured toughened unidirectional prepregs."" In AIP Conference Proceedings, vol. 1960, no. 1. AIP Publishing, 2018. 19.Wang, Yucheng, Fei Tao, Meng Zhang, Lihui Wang, and Ying Zuo. ""Digital twin enhanced fault prediction for the autoclave with insufficient data."" Journal of Manufacturing Systems 60 (2021): 350-359. 20.Seon, Guillaume, Yuri Nikishkov, Andrew Makeev, and Lauren Ferguson. ""Towards a digital twin for mitigating void formation during debulking of autoclave composite parts."" Engineering Fracture Mechanics 225 (2020): 106792. 21.de Sá Rodrigues, Jhonny. ""State Estimation: A Digital Twin approach for an Automated Tape Laying Process."" (2023). 22.Andronas, Dionisis, George Kokotinis, and Sotiris Makris. ""On modelling and handling of flexible materials: A review on Digital Twins and planning systems."" Procedia CIRP 97 (2021): 447-452. 23.Yadav, Neha, and Ralf Schledjewski. ""Review of in-process defect monitoring for automated tape laying."" Composites Part A: Applied Science and Manufacturing (2023): 107654. 24.Fricke, Daniel, and Frederic Fischer. ""Process simulation of the in-situ automated fiber placement process for thermoplastic composites."" (2020). 25.Kirkpatrick, Max, Alex Brasington, Andrew D. Anderson, and Ramy Harik. ""Creation of a Digital Twin for Automated Fiber Placement."" CAMX 2020 (2020). 26.Kumar, Manoj, J. Udhayakumar, J. Nuwad, Rakesh Shukla, C. G. S. Pillai, Ashutosh Dash, and Meera Venkatesh. ""Development of a 147Pm source for beta-backscatter thickness gauge applications."" Applied Radiation and Isotopes 69, no. 3 (2011): 580-587. 27.Shukla, Kritika, and Shankar G. Aggarwal. ""A technical overview on beta-attenuation method for the monitoring of particulate matter in ambient air."" Aerosol and Air Quality Research 22, no. 12 (2022): 220195. 28.Zipf, Mark E. ""Radiation transmission-based thickness measurement systems-Theory and applications to flat rolled strip products."" Advances in measurement systems (2010). 29.Musielak, Stanisław K., and Jerzy Kasprzyk. ""The Use of a Laser to Measure the Speed of a Production Line."" In Advanced, Contemporary Control: Proceedings of KKA 2020—The 20th Polish Control Conference, Łódź, Poland, 2020, pp. 761-772. Cham: Springer International Publishing, 2020. 30.Grant, George R., and Kenneth L. Orloff. ""Two-color dual-beam backscatter laser Doppler velocimeter."" Applied optics 12, no. 12 (1973): 2913-2916. 31.Gangloff Jr, John J., Pavel Simacek, Shatil Sinha, and Suresh G. Advani. ""A process model for the compaction and saturation of partially impregnated thermoset prepreg tapes."" Composites Part A: Applied Science and Manufacturing 64 (2014): 234-244. 32.Merotte, Justin, Pavel Simacek, and Suresh G. Advani. ""Resin flow analysis with fiber preform deformation in through thickness direction during Compression Resin Transfer Molding."" Composites Part A: Applied Science and Manufacturing 41, no. 7 (2010): 881-887. 33.Bishop, Christopher M., and Nasser M. Nasrabadi. Pattern recognition and machine learning. Vol. 4, no. 4. New York: springer, 2006.

Conference: SAMPE 2024

Publication Date: 2024/05/20

SKU: TP24-0000000136

Pages: 14

Price: $28.00