SAMPE Journal - January/February 2020 - 7
INTRODUCTION
Overview
Automated Fiber Placement (AFP) systems were
developed to transition composite construction
from a manual hand layup technique to a faster
more repeatable automated technique. Several
variants of AFP systems exist, but all operate on the
same basic design principle (Figure 1). A stationary
or moving substrate is used as an inner mold
for the composite part to guide the final shape.
Preimpregnated carbon fiber epoxy tape strips (tow
tape) are spool fed to a collimator that aligns them
side by side. The row of fiber tows is then fed to the
AFP 'head' which houses the compaction roller that
travels along the surface of the substrate, depositing
the tows onto the substrate. The substrate or the
roller (or both) move and rotate so that the tows are
deposited on a preset path. Traveling ahead of the
roller is a heat source (usually a quartz lamp) that
preheats the substrate to aid the adhesion of the
ply onto the previous ply or substrate.
Composites constructed with AFP systems
can be prone to manufacturing defects that may
severely compromise the structural integrity of the
part by creating stress concentrations that can lead
to failure. The primary defects of interest are twists
in the tows, gaps between tows, overlapping tows,
reduced ply adhesion quality, and Foreign Object
Debris (FOD). In order to detect and mitigate
the effects of these manufacturing defects, the
standard procedure in aerospace manufacturing
environments is to conduct a full visual inspection
of each layup. This usually involves the use of
multiple technicians with lights and magnifying
optics combing over the entire structure after each
ply layer is deposited. Not surprisingly, this adds
labor and time costs to the manufacturing process.
Figure 1. Simplified diagram of a typical AFP robotic platform.
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SAMPE Journal - January/February 2020
Table of Contents for the Digital Edition of SAMPE Journal - January/February 2020
Table of Contents
SAMPE Journal - January/February 2020 - Cover1
SAMPE Journal - January/February 2020 - Cover2
SAMPE Journal - January/February 2020 - Table of Contents
SAMPE Journal - January/February 2020 - 2
SAMPE Journal - January/February 2020 - 3
SAMPE Journal - January/February 2020 - 4
SAMPE Journal - January/February 2020 - 5
SAMPE Journal - January/February 2020 - 6
SAMPE Journal - January/February 2020 - 7
SAMPE Journal - January/February 2020 - 8
SAMPE Journal - January/February 2020 - 9
SAMPE Journal - January/February 2020 - 10
SAMPE Journal - January/February 2020 - 11
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SAMPE Journal - January/February 2020 - Cover3
SAMPE Journal - January/February 2020 - Cover4
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