Automated fibre placement based composite structures: Review on the defects, impacts and inspections techniques
Source abstract
Abstract
Abstract Automated fibre placement (AFP) offers high throughput, efficient and accurate manufacturing methods for making multi-stiffened laminated composites. However, processing conditions, machine tolerances and steering of tape can induce small random defects within the laminate, which may compromise the structural integrity. Thus, this paper presents a comprehensive review on the processing/steering-induced defects in AFP and their influence on the quality of the final product. Three key processing parameters in AFP, specifically consolidation force, lay-up speed and curing/melting temperature are attempted elaborately. Additionally, the paper attempted to present the discussions on in-situ process monitoring as well as the Machine Learning (ML) based predictive models for AFP based composites.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Advanced Fiber Optic Sensors · Mechanical Behavior of Composites · Structural Health Monitoring Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (100+)
Show source-provided references
1. Carbon fibres and their applications10.1088/0022-3727/20/3/002 ↗
2. Automated processes for composite aircraft structure10.1108/01439910610651428 ↗
3. Grone RJ and Grimshaw MN, inventors. Composite tape laying machine with pivoting presser member. US patent US4627886 A. 6 April 1971.
4. Goldsworthy W, Hardesty E and Karlson H, inventors. Geodesic path length compensator for composite-tape placement method. US patent US3810805 A, 1974.
5. Design principles in filament winding10.1016/0956-7143(94)90014-0 ↗
6. Automated lamination of production advanced composite aircraft structures
7. The engineering aspects of automated prepreg layup: History, present and future10.1016/j.compositesb.2011.12.003 ↗
8. Prusty · 2016 · 1
9. Mazumdar · 2002
10. Winding Technique. CarboFibretec. Available at: https://carbofibretec.de/en/produktionsverfahren/wickeltechnik/.
11. Red · 2014
12. Composite Technology. Ingersoll. Available at: http://www.camozzimachinetools.com/en/camozzigroup/machine-tools/products/composite-technology.
13. High performance thermoplastic resins and their composites
14. Recent development in automated fibre placement of Thermoplastic composites
15. Additive Manufacturing with High Performance Thermoplastic Composites
16. Multi-Material-Head Novel laser-assisted tape, prepreg and dry-fiber placement system
17. Laser-assisted tape placement of thermoplastic composites: The effect of process parameters on bond strength
18. The effect of processing temperature and placement rate on the short beam strength of carbon fibre–PEEK manufactured using a laser tape placement process10.1016/j.compositesa.2015.08.008 ↗
19. ISAAC Advanced Composites Research Capability
20. Structural Analysis and Optimization of Moderately-Thick Fiber Steered Plates with Embedded Manufacturing Defects
21. Advanced AFP Applications on Multifunctional Composites
22. Elmar · 2014
23. Automated manufacturing of an integrated pre-preg structure
24. On the layup of convex corners using Automated Fibre Placement: an evaluation method
25. Introduction of automated 3d vacuum buildup in the composite manufacturing chain
26. A study to determine the influence of robotic lamination programs on the precision of automated fiber placement through statistical comparisons
27. Angell · 2013
28. Experimental study of the effect of automated fiber placement induced defects on performance of composite laminates10.1016/j.compositesa.2011.01.007 ↗
29. Sloan J. ATL and AFP: Defining the megatrends in composite aerostructures. Composites world; High performance composites. Vol 16. Ohio, United States; 2008:68.
30. Fiber Placement
31. Defects in composite structures: Its effects and prediction methods – a comprehensive review10.1016/j.compstruct.2013.06.008 ↗
32. Design and optimization of a thermoplastic tow-placement process with in-situ consolidation10.1177/002199839703100302 ↗
33. Delaminations in composite structures: Its origin, buckling, growth and stability10.1016/1359-8368(95)00035-6 ↗
34. Future Opportunities for Composites Automation
35. In situ consolidation of thermoplastic prepreg tape using automated tape placement technology: potential and possibilities10.1016/j.compositesb.2014.05.025 ↗
36. Bendemra H, Vincent MJ, Compston P. Optimisation of compaction force for automated fibre placement. 8th Australasian Congress on Applied Mechanics: ACAM 8 Melbourne, Australia: Barton, ACT: Engineers Australia; 2014:957-965.
37. Void formation in thermoplastic composites made by automated fiber placement
38. Nixon-Pearson OJ, Belnoue JP-H, Ivanov DS, Hallett SR. The compaction behaviour of un-cured prepregs. The 20th International Conference on Composite Materials Copenhagen, Denmark; 2015.
39. Transitional behaviour of prepregs in Automated fibre deposition processes
40. Effect Of Process Parameters On The Quality Of Laminates Made By Automated Fiber Placement (AFP) Using Out-Of-autoclave (OOA) Prepregs
41. Flexural performance and process conditions of thermoplastic composite laminates processed by automated tape placement
42. Identification of some optimal parameters to achieve higher laminate quality through tape placement process10.1002/adv.20177 ↗
43. Combined optical-thermal model for near-infrared laser heating of thermoplastic composites in an automated tape placement process10.1016/j.compositesa.2014.08.006 ↗
44. Thermal modelling of tape laying with continuous carbon fibre-reinforced thermoplastic10.1016/0010-4361(88)90124-3 ↗
45. Intimate contact development in laser assisted fiber placement
46. Safety & Certification Initiatives for Composite Airframe Structure
47. Composite Development & Applications for Cryogenic Tankage
48. Chauncey Wu K. Design and Analysis of Tow-Steered Composite Shells Using Fiber Placement American Society for Composites 23rd Technical Conference. United State of America; 2008.
49. Measom · 1996
50. Design and Manufacturing of Tow-Steered Composite Shells Using Fiber Placement 50th AIAA/ASME/ASCE/AHS/ASC Structures
51. Tatting BF, Gürdal Z. Automated finite element analysis of elastically-tailored plates NASA Scientfic and Technical Information, NASA/CR-2003-212679; 2003.
52. Limitations of fibre placement techniques for variable angle tow composites and their process-induced defects
53. Langley · 1999
54. Tatting · 2002
55. Tatting · 2002
56. Structural response of compression-loaded tow–placed, variable stiffness panels
57. Thermal Testing of Tow-Placed Variable Stiffness Panels Proceedings of the 42nd AIAA/ASME/ASCE/AHS/ASC Structures
58. Buckling and Postbuckling of Tow-Placed Variable Stiffness Panels Proceedings of the 43rd AIAA/ASME/ASCE/AHS/ASC Structures
59. A theoretical model to study the influence of tow-drop areas on the stiffness and strength of variable-stiffness laminates10.1177/0021998308097675 ↗
60. Variable-stiffness composite panels: Defect tolerance under in-plane and low-velocity impact loading
61. Design and manufacture of a variable-stiffness cylindrical shell
62. Experimental Analysis Of Gaps And Overlaps Caused By Intra-Ply Sectorization In The Thermoplastic Automated Fiber Placement Process
63. The Effect of intraply overlaps and gaps upon the compression strength of composite laminates
64. Defect layer method to capture effect of gaps and overlaps in variable stiffness laminates made by Automated Fiber Placement10.1016/j.compstruct.2012.10.031 ↗
65. Automated In-Process Inspection System for AFP Machines10.4271/2015-01-2608 ↗
66. Far-field and near-field strain response of automated tow-placed laminates to stress concentrations
67. Influence of gap and overlap singularities created by automated fiber placement on the properties of carbon-epoxy laminates
68. Assessing the structural response of automated fibre placement composite structureswith gaps and overlaps by means of numerical approaches
69. Variability of permeability in fibre preforms manufactured with automated fibre placement (AFP)
70. Strength prediction and measurement in model multilayered discontinuous tow reinforced composites10.1177/0021998304038215 ↗
71. Hörmann · 2016
72. Continuous tow shearing for manufacturing variable angle tow composites10.1016/j.compositesa.2012.02.024 ↗
73. Performance benefits from Variable Angle Tow laminates and their implications for Future Manufacturing
74. Analysis of Shear Instability in Compression Due to Fibre Waviness10.1177/073168449301201103 ↗
75. Compression failure mechanisms in unidirectional composites10.1177/002199839202601804 ↗
76. Compressive failure of fiber composites10.1016/S0065-2156(08)70385-5 ↗
77. Maqueda Jiménez · 2014
78. Microbuckling of fiber composites with random initial fiber waviness10.1016/0022-5096(94)90070-1 ↗
79. The effect of fibre waviness on the relationship between compressive and flexural strengths of unidirectional composites10.1177/002199839402800105 ↗
80. Sources of variability in uncured aerospace grade unidirectional carbon fibre epoxy preimpregnate10.1016/j.compositesa.2006.07.010 ↗
81. A technique for characterizing process-induced fiber waviness in unidirectional composite laminates-using optical microscopy10.1177/002199839703101702 ↗
82. Effect of fiber waviness on the compressive strength of unidirectional carbon fiber composites
83. Wang · 2001
84. Compression strength reductions in composite laminates due to multiple-layer waviness10.1016/0266-3538(95)00020-8 ↗
85. Influence of ply waviness on the stiffness and strength reduction on composite laminates10.1177/089270579200500405 ↗
86. Influence of fibre misalignment and voids on composite laminate strength10.1177/0021998314557533 ↗
87. Elastic properties of composites with fiber waviness10.1016/1359-835X(96)00034-6 ↗
88. Effects of material and geometric nonlinearities on the tensile and compressive behavior of composite materials with fiber waviness10.1016/S0266-3538(00)00201-3 ↗
89. Lin · 2006
90. Effect of material characteristics on the layup quality of the continuous multi-tow shearing (CMTS) process
91. Maldague · 2001
92. Non-destructive testing (NDT) techniques in the measurement of residual stresses in composite materials: an overview
93. A new technique to detect defect size and depth in composite structures using digital shearography and unconstrained optimization10.1016/j.ndteint.2011.07.007 ↗
94. Comparison and analysis of non-destructive testing techniques suitable for delamination inspection in wind turbine blades10.1016/j.compositesb.2011.01.025 ↗
95. A review of optical NDT technologies10.3390/s110807773 ↗
96. Current and future trends in non-destructive testing of composite materials10.1016/S0151-9107(01)80007-6 ↗
97. Laser-vision inspection system for automated fiber placement (AFP) process
98. Assessment of cure residual strains through the thickness of carbon–epoxy laminates using FBGs, Part I: Elementary specimen10.1016/j.compositesa.2008.10.008 ↗
99. Cure monitoring of smart composites using Fiber Bragg Grating based embedded sensors10.1016/S0924-4247(99)00266-6 ↗
100. Fibre Bragg gratings in structural health monitoring—Present status and applications10.1016/j.sna.2008.04.008 ↗