Abstract
The effect of thermal contact resistance (TCR) correlated to the degree of intimate contact (DIC) between the incoming tape and the substrate on the temperature history during laser-assisted fiber placement (LAFP) was investigated. A novel experimental methodology was designed to understand the effect with a non-contact method which did not influence the local consolidation quality. To assess the influence of TCR numerically, a three-dimensional optical-thermal model was developed. Experimental results indicated that, for the same tape temperature near the nip point, an increase in the compaction force resulted in a decrease in the temperature at the roller exit and the following cooling phase, in correlation with an increase in the final DIC. Also, the effect of the laser power on the final DIC was less pronounced than the compaction force. In the thermal model, when TCR at the tape-substrate interface was not considered, the temperature predictions underestimated the experimental measurements.
Highlights
The current production rates of lightweight composite structures are far from meeting the demand of the commercial aerospace industry
The compaction force changes a number of parameters during the laser-assisted fiber placement (LAFP) process by altering thermal contact resistance (TCR) via applied pressure and changing the roller geometry
Recent studies proposed that the roller deformation due to increasing compaction force has an influence on the tape temperature during the LAFP process [27]
Summary
The current production rates of lightweight composite structures are far from meeting the demand of the commercial aerospace industry. Automated solutions are needed to increase the pro duction rates to the required level. Automated Fiber Placement (AFP) is a suitable candidate for pro duction of typical aerospace components [3]. In situ consolidation (without a post-consolidation step in an autoclave, oven or press) is achievable with laser-assisted fiber placement (LAFP) if thermoplastic composites are used. This method has the potential for providing further reduction in cycle time, energy consumption and cost.
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