The work will advance the processing science and technology of thermoplastic composites through fundamental studies of the on-line consolidation of thermoplastic composites using lasers. The laser-based system provides localized melting and resolidification and produces void-free parts. It offers the opportunity to control the fiber placement and microstructure with high precision, leading to fabrication of thermoplastic parts that have superior structural integrity. This process reduces the number of processing steps, leading to increased production rates and reduction of residual stress: both major concerns in economical fabrication of high-performance composite parts. The results of the research will lead to increased consolidation speeds, use of wider prepreg tows, and fabrication of large scale, non-cylindrical components using varying consolidation speeds. The process may ultimately allow the low cost fabrication of high performance composite parts.
