The challenges with fast heating rates in the processing of thermoplastic composites
B.C.P. Jongbloed (TU Delft - Intelligent Manufacturing systems)
K.N. Asfew (TU Delft - Intelligent Manufacturing systems)
Julie J.E. Teuwen (TU Delft - Group Teuwen)
D.M.J. Peeters (TU Delft - Group Peeters)
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Abstract
To meet high production rate demands for single-aisle aircraft, this paper looked into automated fiber placement for composite parts and continuous ultrasonic welding for fast assembly, both leveraging rapid heating rates. We highlighted some of the challenges and opportunities in manufacturing thermoplastic composites with these
advanced methods. Fast heating can change the microstructure of tapes (increased voids and surface roughness) prior to consolidation. Due to the high temperature and fast speeds, limited consolidation times are available to cool down effectively or resolve the changed microstructure, resulting in poor quality (intimate contact). This
could be measured in the cooling phase, through a reduced cooling rate with tapes with low intimate contact.
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