Three-dimensional heat transfer analysis of Hot Gas Torch (HGT)-assisted Automated Fiber Placement (AFP) for thermoplastic composites

Automated Fiber Placement (AFP) is a key additive manufacturing process for the production of complex composite structures. This study focuses on the in -situ AFP process for thermoplastic composites with Hot Gas Torch (HGT), which includes heating, consolidation, and solidification steps. Temperature control is critical to achieving high quality parts as it affects bond quality, crystallization, and solidification. However, previous studies have oversimplified convective heat transfer by assuming a constant coefficient, resulting in discrepancies between simulations and experiments. This paper introduces a novel distribution function to model the convective heat transfer coefficient, thereby improving temperature predictions. An optimization loop is used to determine the parameters of the function, which ensures agreement with experimental data. The proposed approach accurately predicts the temperature distribution, which is validated against unseen experimental results. By incorporating the distribution of the convective heat transfer coefficient, this study improves the understanding of heat transfer mechanisms in AFP for thermoplastic composites, leading to improved manufacturing processes and part quality.