Effect of Automated Fiber Placement (AFP) Manufacturing Induced Imperfections on Composite Performance

Abstract

Automation of composite manufacturing provides speed, agility and precision to produce large aerospace and automotive structures. While automated fiber placement (AFP) is a key technology, there are still barriers to widespread industrial adoptions. One such barrier is the understanding of processing parameters on development of unintended imperfections during manufacturing. In this paper, experimental results on influence of process induced imperfections when using AFP technology will be presented. Controlled carbon fiber composite panels with imperfections like gaps, overlaps and missing tows were manufactured using AFP machine. Panels without imperfections were also manufactured using traditional hand-layup, for baseline measurements. Microscopy was also conducted for accurate measurement of imperfection microstructure produced due to curing and consolidation. Specimens were cut from the panels for tests in tension and compression. The paper will report initial test results for variation of tension and compression stiffness and strength, due to the presence of manufacturing induced imperfections.