DESIGN AND OPTIMIZATION OF A THERMOPLASTIC TOW-PLACEMENT PROCESS WITHIN-SITU CONSOLIDATION

Thermoplastic tow-placement with in-situ consolidation offers the pote ntial for rapid fabrication of composite parts for a variety of applic ations. Physical models and model-based and experimental analysis of t he process phenomena have been previously reported by the authors and other investigators in the literature. This paper presents a methodolo gy for practical design and optimization using the available theoretic al process models. Processing windows are developed based on considera tions of material degradation through weight loss, final void content, and dimensional change of the tows, all of which determine laminate q uality and thus, part performance. Optimum line speed and heat input v ariations with composite thickness are identified based on parametric studies to maximize interfacial bond strength and minimize fabrication time, subject to constraints on the above-mentioned quality-related p arameters. The processing windows and optimum profiles are presented i n terms of the controllable process variables, which allows for a read y implementation of the results in practice.