A Coupled Optimization Method for Multiple Consolidation Parameters of Composites Based on Taguchi Algorithm

In situ consolidation automated fiber placement of thermoplastic composites (ICAT) is one of the key engineering technologies for the widespread application of environmentally friendly materials in important fields such as aerospace. Nevertheless, the high melting point and low viscosity characteristics of high-performance thermoplastic composites such as PEEK are key challenges limiting the large-scale industrialization of ICAT technology. As a consequence, researching the defect formation mechanism and suppression methods of the interlayer fusion process of ICAT technology in new high-performance low-melting-point thermoplastic matrix composites is an important direction for promoting the large-scale application of thermoplastic composites. Hence, this paper investigated the ICAT in situ forming process of low-melting-point polyaryletherketone matrix (LM/PAEK) composites. The temperature history was analyzed using a high-frequency temperature acquisition system. Simultaneously, the Taguchi algorithm was used to analyze the coupled effects of multiple consolidation parameters. The results indicate that consolidation temperature is the most significant factor affecting void and interlayer performance. The consolidation parameters primarily influence the extrusion and permeation behavior of the matrix. Furthermore, the optimized consolidation parameter combination is as follows: consolidation temperature of 400°C, consolidation speed of 100 mm/s, and consolidation force of 300 N. Additionally, under the optimized consolidation parameter combination conditions, the porosity and interlayer shear strength were 1.42% and 39.53 MPa, respectively. The porosity was reduced by 78.39%, and the interlayer shear strength was increased by 50.59%.