Session: 03-02-02: Advanced Manufacturing II

Paper Number: 110464

110464 - Unraveling the Foundations for In-Situ Consolidated Automated Fiber Placement 

The use of Automated Fiber Placement (AFP) has a long history in manufacturing aerospace structures from thermosetting tapes, but with recent advances, it is now possible to consolidate thermoplastic composites (TPCs) in-situ during the layup process, known as in situ consolidated automated fiber placement (ICAT). The benefits of TPCs over thermosetting composites, including higher toughness, recyclability, weldability, and ease of repair, combined with the ability to eliminate the need for autoclave processing, make ICAT an attractive option for the aerospace industry. This presentation will examine the interlaminar and in-plane mechanical behavior of ICAT-produced samples made from carbon fiber reinforced low-melting polyaryletherketone (LM-PAEK) tapes, in response to different AFP processing conditions. The results of tensile, compression, and in-plane/interlaminar shear tests, as well as mode I and mode II fracture toughness tests, will be presented and discussed. Through multi-scale experiments and numerical modeling, the interfacial and bonding mechanisms in ICAT samples will be explored and compared with those from traditionally made compression molded samples. If time permits, innovative approaches for the fabrication of cost-effective tooling for ICAT processing will also be discussed. The aim of this research is to fill the gap between ICAT processing, structure, and properties of resulting samples. With a focus on high-speed, repeatable manufacturing of complex structures with aerospace quality, the goal is to uncover the foundation of ICAT and its potential for the future.

Presenting Author: Pratik Koirala The University of Texas at Austin

Presenting Author Biography: Pratik Koirala is pursuing his PhD in the Walker Department of Mechanical Engineering under the guidance of Professor Mehran Tehrani. His area of research encompasses a comprehensive examination of interfacial phenomena in both thermosetting and thermoplastic composites with a specific emphasis on enhancing their additive manufacturing processes. Pratik's research methodology integrates numerical modeling with multi-scale experimental characterization to gain a deeper understanding of his subject matter.

Authors:

Mehran Tehrani University of California at San Diego
Pratik Koirala The University of Texas at Austin