Automated fiber placement (AFP)—Effects of features and defects

Abstract

Automated Fiber Placement (AFP) manufacturing methods, considered to be one of the most advanced methods of composite manufacturing, are used in fabricating complex and large scale composite structures. During AFP manufacturing, the gaps between each fiber-tow is closely controlled. However, due to machine/operational errors, gaps between these fiber-tows exceed set tolerances and are seen as a frequent feature/defect in AFP fabrication. By understanding the effect of these AFP induced gaps, we will be able to evaluate the integrity of the specimens/structures to better understand the effects due to these features/defects. Current research focuses on AFP-gap configurations associated with missing tows and mainly looks into establishing methods for developing knockdowns/design allowable that can be incorporated into the design building block analysis and test validations.