Optimization of process parameters for laser-assisted in-situ consolidation of carbon fiber reinforced composites

Carbon fiber reinforced composites have attracted much attention for their excellent mechanical properties. Laser-assisted in-situ consolidation technology provides an important impetus for the development of the application of carbon fiber reinforced composites. In the process of laser-assisted in-situ consolidation, each process parameter has a different degree of influence on the final performance of the manufactured components, and the optimization of process parameters is the key to improving the quality of laser-assisted in-situ consolidation. In this paper, based on laser-assisted in-situ consolidation equipment, carbon fiber reinforced polyether ether ketone (CF/PEEK) prepreg tape was used as the raw material to prepare laminates. Experiments were designed according to the response surface method (RSM). With the interlaminar shear strength (ILSS) and porosity as the objective functions, a multivariate regression prediction model of laser heating temperature, consolidation force, and laying speed on the performance of molded components was established. The model was subjected to analysis of variance (ANOVA) and sensitivity analysis to verify its accuracy and reliability. The analysis results show that ILSS and porosity are most sensitive to heating temperature. Finally, with high ILSS and low porosity as the optimization objectives, the NSGA-II algorithm was used for multi-objective process parameter optimization, and the optimal process parameter solution was obtained: the ILSS is 62.8 MPa and the porosity is 2.28% under the consolidation force of 239 N, the laying speed of 20.4 mm/s, and the heating temperature of 427°C. The reliability of the optimal solution was proved experimentally.