In-situ thermography of automated fiber placement parts

Abstract

Automated fiber placement (AFP) provides precision and repeatable manufacturing of both simple and complex geometry composite parts. However, AFP also introduces the possibility for unique flaws such as overlapping tows, gaps between tows, tow twists, lack of layer adhesion and foreign object debris. These types of flaws can all result in a significant loss of performance in the final part. The current inspection method for these flaws is a costly and time intensive visual inspection of each ply layer. This work describes some initial efforts to incorporate thermal inspection on the AFP head and analysis of the data to identify the previously mentioned flaws. Previous bench-top laboratory experiments demonstrated that laps, gaps, and twists were identified from a thermal image. The AFP head uses an on- board lamp to preheat the surface of the part during layup to increase ply consolidation. The preheated surface is used as a thermal source to observe the state of the new material after compaction. We will present data collected with the Integrated Structural Assembly of Advanced Composites (ISAAC) AFP machine at Langley Research Center showing that changes to the temperature profile is sufficient for identifying all types of flaws.