Performance evaluation of an as-built composite component fabricated by automatic fiber placement
Lua, Jim Y. Li, Rui Karuppiah, Anand Vijay Kariyawasam, Supun Albrecht, Quinten
Lua, Jim Y.
Li, Rui
Karuppiah, Anand Vijay
Kariyawasam, Supun
Albrecht, Quinten
Other Names
Location
Time Period
Advisors
Original Date
Digitization Date
Issue Date
2025-01-03
Type
Conference paper
Genre
Keywords
Composite structures,Aerospace industry,Finite element analysis,Mesh generation,Glass fiber,Stress concentration,Composite manufacturing,Aircraft structures,Composite materials,Image analysis
Subjects (LCSH)
Citation
Jim Lua, Rui Li, Anand Karuppiah, Supun Kariyawasam and Quinten Albrecht. "Performance Evaluation of an As-Built Composite Component Fabricated by Automatic Fiber Placement," AIAA 2025-1032. AIAA SCITECH 2025 Forum. January 2025.
Abstract
Low-cost composite structures are highly demanded by the DoD and commercial industries to reduce total life cycle costs through the integration of automation and digital manufacturing of unitized composite parts. Automatic fiber placement (AFP) has been used extensively by major aerospace industries to produce large-scale composite structures. Through the automatic placement of fibers in different directions on the customized mold surface, full-scale unitized composite structures can be fabricated with higher production rates and in a highly controllable and repeatable manner. However, poor process planning and time-consuming, operator-dependent manual inspection can significantly interrupt the manufacturing process and increase the scrap rate due to intolerable levels of fabrication-induced defects. A demonstration of AFP technology was performed using a dual-material composite tapered beam. The performance of the as-built beam was evaluated using a physics-based failure prediction model under multiaxial loading. Our key research components include the fabrication of dual-material tapered beams using the improved AFP technology, performance of NDI inspection and characterization of fabrication-induced defects, development of a high-fidelity model with defects mapping, and performance of failure prediction under multiaxial loading. The predicted failure sequence and final rupture mechanisms are compared with the experimental observations. © 2025, American Institute of Aeronautics and Astronautics Inc, AIAA. All rights reserved.
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Publisher
American Institute of Aeronautics and Astronautics Inc, AIAA
Journal
Book Title
Series
AIAA Science and Technology Forum and Exposition, AIAA SciTech Forum 2025
6 January 2025 through 10 January 2025
Orlando
325579
6 January 2025 through 10 January 2025
Orlando
325579