Automation of Thermoplastic Composite Processing

Abstract

An experimental model of a new automated pre-preg lay-up process is developed to determine the effects of process parameters on the consolidation and quality of parts made of polyetheretherketone (PEEK) reinforced with carbon fibers (APC-2). Temperature, tape velocity, and applied pressure affect the degree of consolidation of the laminates produced using this process. The consolidation's dependence on applied pressure is clearly demonstrated. A threshold pressure of approximately 275 kPa (40 psi) exists for APC-2, below which consolidation does not occur. This threshold is followed by a sharp increase in consolidation up to an applied pressure of 900 kPa (130 psi), and a much slower rate of increase in consolidation for pressures in excess of 900 kPa. The effect of velocity is qualitatively explored. The results of the experiment are discussed with reference to the development of robotic lay-up cells and continuous processes for the production of quasi-isotropic laminated sheet.