Influence of Process Parameters on Process-induced Defects in AFP Manufactured CF/PEKK Composites


Şükür E. F. , Elmas S., Eskizeybek V., Yıldız M., Şaş Çaycı H. S.

1st International Conference on Innovative Academic Studies, Konya, Turkey, 10 - 13 September 2022, pp.1

  • Publication Type: Conference Paper / Summary Text
  • City: Konya
  • Country: Turkey
  • Page Numbers: pp.1
  • Çanakkale Onsekiz Mart University Affiliated: Yes

Abstract

Automated fiber placement (AFP) is an advanced manufacturing process, allowing large-scale and rapid composite structure fabrication without scarifying accuracy using aerospace-grade carbon fiber reinforced prepregs. However, one of the process limits is the occurrence of unexpected process-induced defects in the prepreg tows during the lay-up process such as gap and overlap defects, resulting in a decrease in the mechanical properties of the composites. Producing defect-free parts or minimizing the effects of the defects can be achieved by optimizing the process parameters without interrupting the fabrication process. To determine the optimum process parameters, a clear understanding needs to link between process parameters and the defects. This study aims to investigate the influence of process parameters, including lay-up speed and compaction force, on the mechanical performance of carbon fiber/polyether-ketone-ketone (CF/PEKK) composites. For this purpose, gap/overlap defects embedded composite laminates were produced with two different lay-up speeds (0.1 m/s, 0.4 m/s) and compaction forces (300 N, 600 N). The effects of the parameters were examined in detail with differential scanning calorimetry (DSC), Fourier-transform infrared spectroscopy (FTIR[VE1] ), dynamic mechanical analysis (DMA), and short beam shear tests. The optimum process parameters were determined as 0.1 m/s, and 600 N in the AFP process regards the comprehensive tests and analysis results. In case of a possible gap and overlap defect during the laying process, the effect of defects can be minimized if the compaction force is set to 600 N and the lay-up speed is 0.1 m/s on the adjacent layer.


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