ACM7 conference at SAM XL

Paving the way towards industrial solutions with Automated Fiber Placement!

Laser heating is the most common method in AFP with in-situ consolidation due to its precision and speed, but it poses safety challenges. The Excelitas Technologies Corp. humm3 pulsed flashlamp offers a promising broadband, programmable, and relatively safer alternative.

Researchers Daniël Peeters, Julie Teuwen and SAM XL engineer Kasahun Asfew created a static setup replicating AFP conditions. They investigated the thermal response of the composite tape as a function of the programmable parameters: voltage, pulse width and pulse frequency. Deconsolidation of the tape under humm3 heating was assessed from micrographs and surface topography, quantified by thickness change, void content, waviness, and roughness.

Results

Results showed that voltage is the dominant parameter influencing the thermal response, whereas pulse width and frequency (when combined such that the total fraction of time the flashlamp is on is constant), showed no significant effects when the total energy input was held constant. Compared to laser heating, humm3 produces less severe deconsolidation.

We believe that these results are promising to apply the lightweight character of composites on a large industrial scale. A great example of how SAM XL is collaborating with scientists at TU Delft | Aerospace Engineering on the industrialisation of this innovation, for new aircraft programmes and beyond. Further research will determine how to apply this technology – lowering the investment threshold for industry.

Results were presented by Daniël Peeters presented the results during the ACM7 conference at our facility. Special thanks to our Automated Manufacturing Engineer André Florindo for his contribution to this research.

Read more in the Composites Part A article “Thermal response and deconsolidation of thermoplastic composite tape during pulsed flashlamp (HUMM3) heating in automated fiber placement (AFP)”: