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Session: Session 7: Thermoplastic Composites
Session starts: Wednesday 15 April, 16:10
Presentation starts: 17:10
Room: Main

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Arash Khodaei ()
Allyson Fontes (Concordia University)
Farjad Shadmehri (Concordia University)

Abstract:
Automated Fiber Placement (AFP) of thermoplastic composites presents a promising route toward more energy-efficient manufacturing, primarily by allowing consolidation to occur in-situ and eliminating the need for secondary autoclave processing. Despite this advantage, key challenges remain, particularly in achieving high interlaminar bond quality. Rapid processing conditions often limit intimate contact and polymer chain diffusion at ply interfaces, leading to lower interlaminar strength and stiffness compared to autoclave-reconsolidated laminates. To address these bonding deficiencies, this work introduces vibration-assisted thermal bonding (VATB) as an innovative approach to enhance interlayer consolidation in thermoplastic composites. Experimental evaluation through lap shear testing, supported by microstructural characterization, indicates that controlled vibration facilitates improved polymer mobility and interfacial diffusion. The application of VATB in both bonding and repair scenarios demonstrates increased bond strength along with reduced void content. In addition, the influence of repass as an in-situ technique is examined, with its effects on lap shear performance analyzed through mechanical testing and micrographic observations.