Prediction of In‐Plane Shear Mechanical Properties Through Degree of Bonding Characterization as a Function of Automated Fiber Placement Processing Parameters for Carbon Fiber/ PEKK Composite Laminates

ABSTRACT Automated Fiber Placement (AFP) of fiber‐reinforced thermoplastic tapes enables rapid manufacturing by leveraging precise robotic lamination and in situ consolidation. Accordingly, understanding the effects of processing parameters on resulting mechanical properties is essential. While experimental characterization of all resulting structures as a function of processing parameters is possible, it is infeasible due to the resources needed. Hence, predictive tools can provide valuable insight, enabling the widespread adoption of AFP‐based manufacturing. In this work, we correlated interlaminar bonding of AFP‐manufactured Carbon Fiber Reinforced Polyetherketoneketone (CF/PEKK) with processing parameters such as consolidation time, pressure, and temperature. In addition, an existing analytical model that predicts the level of bonding was modified to fit our material and the resulting experimental data. The modified model captures the degree of bonding developed under both isothermal and non‐isothermal consolidation conditions and relates it to matrix properties. These were subsequently used to predict elastic behavior as a function of in‐plane shear behavior and were validated against a finite element model which uses cohesive zone elements to represent interlaminar cohesion. This approach allows for simplified characterization of elastic properties for CF/PEKK laminates with matrix dominated behavior using in‐plane shear testing in contrast to out of plane and transverse shear processes.