Effects of defects in automated fiber placement laminates and its correlation to automated optical inspection results

Automated Fiber Placement (AFP) is a widely used production process for the manufacturing of large scale CFRP parts. However, the occurrence of manufacturing defects such as gaps or overlaps is still a common problem in today’s AFP production environments. This study investigates the effect of different defect configurations on the mechanical performance (i.e., tensile strength, flexural strength, and shear strength) of AFP laminates. The results are then linked to the data generated “inline” by a ply inspection system. We use the Pearson correlation in order to relate the measured defect volume to the strength of samples containing different types of defects. A clear knockdown in tensile strength was found for specimens with gaps or overlaps that caused a high amount of fiber undulations in the laminate. The sensor data analysis showed a similar trend. Specimens with a high defect volume had significantly lower values for the tensile strength. A correlation coefficient of −0.98 between these two values was calculated. The obtained results are a promising step towards automated quality inspection for the AFP process.