Influence of processing parameters on the tape width in flashlamp-assisted automated tape placement

Abstract Automated tape placement is capable of manufacturing high-performance composites. The degree of bonding and lay-up accuracy are critical quality criteria for achieving defect-free high-quality parts. Gaps and overlaps reduce the mechanical performance, which indicates the need for a precise definition of the processing parameter influences on the consolidated tape width. The influences of a flashlamp automated tape placement system on the tape width after consolidation for carbon fiber reinforced thermoplastic tapes are investigated. The process is analysed using a Taguchi design of experiments approach. Emphasis is placed on the variation within the tape width and the total tape width change. Special consideration is placed on the flashlamp heating parameters; voltage, frequency and pulse width. Temperature, consolidation pressure and width measurements are used to investigate the influences of those parameters. The results show that the consolidation force and heating system power/temperature followed by the consolidation roller hardness and lay-up speed have the highest influence on the tape width after consolidation and its variability. The voltage of the heating system has no significant influence on the tape width change. The frequency of the system has a higher influence compared to the pulse width on the tape width change. A high tool temperature leads to a reduction in tape width after consolidation. This research provides a comprehensive understanding of the factors influencing the tape width in flashlamp automated tape placement, offering valuable insights for optimizing manufacturing parameters to produce high-performance composites.