Void stability process window and parametric optimization for filament‐wound composite riser

Abstract The manufacturing process parameters play a critical role in determining the quality of resin‐matrix composite structures. This study aims to investigate the impact of process parameters on void content and identify the stable and minimal void content of nano‐reinforced filament‐wound risers. Fourteen process parameters were initially designed, taking into account winding tension, speed, and curing time, based on the Box–Behnken design method. Subsequently, a void content model was developed using the response surface method, utilizing experimental data. The study further explores the effects of individual and combined process parameters on void content and establishes a stable process window through sensitivity analysis. Finally, the PSO‐GWO algorithm is employed to optimize winding tension, speed, and curing time with the objective of reducing void content. The results of the numerical analysis highlight the significant influence of curing time on void content, and the optimal parametric combination is determined to be 48.4 N winding tension, 12.6 m/min winding speed, and 6.7 h of curing time. Highlights Winding tension and rate have a similar impact on porosity content. Void content sensitivity to tension is affected by feed rate and curing time. The stable process windows are winding tension [28 N, 53 N], feed rate [30%, 78%], and curing time [5.1 h, 8.4 h]. The optimal parameters combination is 48.4 N, 63%, and 6.7 h.