Fibre alignment and void assessment in thermoplastic carbon fibre reinforced polymers manufactured by automated tape placement

Automated Tape Placement (ATP) technology is one of the processes that is used for the production of the thermoplastic composite materials. The ATP process is complex, requiring multiple melting/crystallization cycles. In the current paper, laser-assisted ATP was used to manufacture two thermoplastic composites (IM7/PEEK and AS4/PA12). Those specimens were compared to specimens that were made of thermoset polymeric composites (IM7/8552) manufactured while using a standard autoclave cycle. In order assess the quality, void content, fibre distribution, and fibre misalignment were measured. After manufacturing, specimens from the three materials were assessed using optical microscopy and computed tomography (CT) scans. The results showed that, as compared to the thermoset composites, thermoplastics that are manufactured by the ATP have a higher amount of voids. On the other hand, manufacturing using the ATP showed an improvement in both the fibre distribution inside the matrix and the fibre misalignment.