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Investigations of the tape placement process are still underway to achieve the laminate quality comparable with other highly developed composite manufacturing methods, such as autoclave-based processes. The evaluation of the products and the mechanical properties of the material has revealed regions where some upgrading could bring significant enhancement in performance. This study is concerned with issues related to the characterization of material properties, interlaminar bond development, and ways of optimizing process parameters. These include heating, layup velocity, tool temperature, and consolidation force, which were studied to determine their effects on the mechanical strength of the composites produced. The bonding degree of the laminates was simulated taking into account a combination of process parameters, comparing the predictions with the actual test results. The thermal stability of the polyether ether ketone matrix, in relation to the processing conditions used in the manufacture, and their effects on the interlaminar bonding

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The possibility of assembling through welding is one of the major features of thermoplastic composites and it positively contributes to their cost-effectiveness in manufacturing. This article presents a comparative evaluation of ultrasonic, induction and resistance welding of individual carbon fibre-reinforced polyphenylene sulphide (PPS) thermoplastic composite samples that comprises an analysis of the static and dynamic mechanical behaviour of the joints as well as of the main process variables. The induction welding process as used in this research benefitted from the conductive nature of the reinforcing fibres. Hence, no susceptor was placed at the welding interface. Resistance welding used a fine-woven stainless-steel mesh as the heating element and low welding pressures and times were applied to prevent current leakage. Triangular energy directors moulded on a separate tape of PPS resin were used to concentrate ultrasonic heat at the welding interface. The static single-lap shear strength of the joints was found similar for induction and ultrasonic welding. A 15% drop in the static mechanical properties of the resistance welded joints was attributed to incomplete welded overlaps following current leakage prevention. However, the fatigue performance relative to the static one was similar for the three sorts of joints. A comparative analysis of process variables such as welding time, required power and energy was also carried out.

One of the ways to identify the quality of structures made from fibre-reinforced thermoplastic material is by examining its void content percentage. Significant improvement in mechanical properties can be achieved by minimising it. The purpose of this work was to develop a simulation tool from existing available model in literature, to trace out the void development inside the laminate during the manufacturing and identification of major influencing process parameter. The effects of consolidating force, process velocity, hot gas flow in the heating region, and repetitive passes were investigated through simulation. A series of experiments was carried out on several AS4/PEEK laminated plates manufactured by automatic tape placement process. Simulated void distribution through thickness and density were compared with measured values to trace the effecting input parameters. Thickness build-up with successive lay-ups is also monitored online and the average thickness lies in close proximity to the predicted range. Major influencing process parameters were identified.