Two-stage model of prepreg bonding interface formation in automated fiber placement process

While Automated Fiber Placement (AFP) of thermoset matrix composites are widely used in the aviation industry, there is little conclusive research on the relationship between the physical model of bonding interface formation process and the actual bonding strength between prepreg layers formed in AFP process. Although massive amounts of experimental data on prepreg tack have been achieved from existing research, engineers are unable to use these data as a decisive criterion in choosing process parameters. In this research, a prepreg layup physical model based on reptation model and viscoelastic mechanical model is built, in which the bonding interface formation process is divided into two stages, namely, diffusion and viscous stage. Layup-peeling experiments are conducted via a special designed high-speed layup experimental platform so that practical AFP process parameters can be imitated, and a logarithmic curve of layup velocity-peeling energy under different layup pressure is achieved. The slope of the logarithmic curve and the surface morphology of the sample after peeling prove the correctness of the established model. Simultaneously, the experimental data proves that when prepreg is peeled off, the transition from the cohesive failure mode to the interface failure mode occurs at the laying speed between 100 mm/s and 200 mm/s. These results can be used as a reference for choosing AFP process parameters to realize the balance between good bonding quality and harmless separation of adjacent prepreg layers.