In-Situ Advanced Fiber Placement Utilizing Ultrasonic Lamination Technology

Foster-Miller proposes to demonstrate a method for automated tow placement (ATP) of advanced composites utilizing an ultrasonic energy source which serves as the energy source for heating and provides "on-the-fly" consolidation. Foster-Miller has already demonstrated the basic technology for thermoplastic composites. Advance rates from 90 to 120 in./min have been demonstrated with the UTL process for APC2 composite materials, where laminate quality and properties are equivalent to other tape laying techniques. The proposed Phase I program will establish the basis for controlling the UTL process and will clearly define the engineering approach to scale-up and commercialization of the technology. The Phase II program will seek to scale-up the technology for interface with existing tape laying equipment. Additionally, Poster-Miller intends to demonstrate the applicability of the technology to lay-up and debulking of pseudo thermoplastic composites, such as Avamid KIII, and for staging of thermosetting composite prepregs. Due to the inherent limitations associated with state of the art processes such as the hot gas torch approach, Bell, Boeing, and Lockheed, are all eager to participate in the development of Foster-Miller's Ultrasonic Lamination technology, and have joined the Foster-Miller team for the proposed program.