Qualification Method for Automated Fibre Placement to Optimize Process Parameters Regarding Layup Quality

Automated Fibre Placement (AFP) is an advanced process for the manufacturing of high-performance composite structures and is established in the aerospace industry. The main challenge is the optimization of the process parameters, such as layup speed, compaction force and heating temperature, to minimize the common AFP layup defects. The evaluation of these defects is an important topic during the development of new components. Defect detection is usually done by visual inspection of the layup and manual recording of the occurred defects. This paper developed a methodology to determine the defect characteristics, focused on out-of-plane wrinkles, which are typical during a curved layup of thermoset tape material in respect to process parameters, geometry and material width. This methodology offers the possibility to compare different materials and process parameters on a basic level to get a detailed understanding of the influence on layup quality within the AFP process.