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Comparing manufactured parts to their engineering specifications is the basis for Quality Control. Traditionally, Geometric Dimensioning and Tolerancing (GD&T) standards define how engineering tolerances are used for generating fabrication specifications. Due to the complexities inherent to the composite layup process, Automated Fiber Placement (AFP) machines require a new paradigm of quality control. In addition to the traditional finished part dimension and quality reports, the AFP process requires a ply-by-ply inspection of the as-built laminate to ensure that each laydown remains within the manufacturing allowable specifications. To address this problem, Fives and the National Research Council Canada have proposed an In-Process Inspection system based on Optical Coherence Tomography (OCT) technology capable of performing high-resolution surface profilometry and automatic alignment of the as-manufactured measurements to the as-designed engineering model. With both an accurate surface profile and positioning of the measurement data in the CAD design reference, the differences can be analyzed to detect manufacturing anomalies and minimize process variability. Later on, this information has the fidelity required for an exact digital transformation of the process. This paper will review a few aspects of the Measurement System Analysis performed to validate the sensor’s reliability as well as review the high level methodology undertaken to establish the relationship between the IPI system’s sensor and the machine tool center point during fabrication. Finally, examples will be used to demonstrate the approach to obtain course, ply, and laminate level aggregations. Copyright 2021. Used by CAMX – The Composites and Advanced Materials Expo, 8th Annual Composites and Advanced Materials Expo (CAMX 2021), October 19-21, 2021, Dallas, Texas

This paper presents the preliminary stages of the collaboration between the National Research Council Canada (NRC) and the German Aerospace Center (DLR). A study demonstrating the current status of continuous resistance welding and the efforts to increase the process maturity is presented. Furthermore a continuous resistance welding end-effector concept developed at the DLR’s Center for Lightweight Production Technology (ZLP) Augsburg is discussed in this work.

Automated Fiber Placement (AFP) is used to manufacture large and complex parts in the aerospace industry. A time-consuming portion of this fabrication process remains the inspection and quality control, which are largely performed visually after each deposited layer. This conference proceeding showcases a disruptive, responsive, and reliable solution based on the Fives In-Process Inspection system enabled by the National Research Council of Canada (NRC) Optical Coherence Tomography (OCT) sensor to perform in-process defect monitoring of the fiber layup. Measurements are taken close to the material deposition location without inhibiting the optimal machine path or slowing down the layup process. Assessment of the quality of a deposition takes place concurrently while the layup head applies material. This responsive feedback loop enables adaptive control of the AFP fabrication process. Technical details on how the OCT based inspection system's data flow has been integrated within the manufacturing process of a Fives Viper AFP machine are provided to explain the system's real-time response and high-resolution measurements. Results obtained in an industrial setting using the sensor installed on a production AFP machine are presented., International SAMPE Conference and Exhibition 2020 ["Manufacturing Technology" track within the SAMPE 2020 Virtual Series]

Achieving the high production rates promised by automated fibre placement (AFP) is often hindered by lengthy and variable manual intervention, predominantly 100% visual inspection of every deposited ply; introducing machine stoppages, the risk of quality escapes, and the cost overhead of employing a manual inspection system with low fidelity measurement aids. An in-situ inspection system embedded in the manufacturing process is a vital enabler to achieve world class manufacturing performance. This paper describes a new and innovative measurement solution based on an optical, interferometric imaging technique called optical coherence tomography (OCT). The system’s characteristics facilitate the design of a compact probe which can be easily integrated onto the AFP head and allow measurements very close to the compaction roller nip point. The high fidelity system shows little sensitivity to differences in material reflectivity and sensor to part incident angle. This paper will cover the initial implementation and system demonstration in a TRL 6 production mature environment using a Viper AFP machine from Fives-Cincinnati. Results will demonstrate the ability of this novel inspection system to accurately detect and measure defects to verify part inspection compliance., 6th Annual Composites and Advanced Materials Expo, CAMX 2019, September 23 - 26, 2019, Anaheim, California