This thesis investigates the mitigation of in-plane fiber waviness in the press consolidation of Carbon Fiber Polyetherketoneketone (PEKK) V-tail front spars. The manufacturing process includes Automated Tape Laying (ATL), preforming, and press consolidation. The study identifies
...
This thesis investigates the mitigation of in-plane fiber waviness in the press consolidation of Carbon Fiber Polyetherketoneketone (PEKK) V-tail front spars. The manufacturing process includes Automated Tape Laying (ATL), preforming, and press consolidation. The study identifies that fiber waviness originates during the press consolidation phase, particularly on the outer mold line (OML) side. Three hypotheses were investigated: waviness due to matrix flow, flange compression, and tool-part interaction during tool expansion. Mitigation strategies include installing guidance pins, placing shim material, modifying the pressurization sequence, central fixation of the female tool, and spot welding the ATL stack. These actions successfully eliminated fiber waviness, as confirmed by subsequent consolidations. An image processing algorithm was developed for consistent measurement. The study concludes that uniform compaction, uniform tool gap, and maintaining a consistent temperature range are essential to preventing fiber waviness in composite spar manufacturing.