The main objective of the present study is to establish the relationships between the process variables and the quality of thermoplastic composite laminates fabricated by tape placement. The quality parameters considered in the process modeling are interlaminar bond strength, weight loss through thermal degradation, and crystallinity. Stress, heat transfer, crystallization, degradation, and bonding models are developed. These models relate the process parameters (e.g., roller velocity, roller pressure, heat input) to temperature, stress, and crystallinity distributions, degradation weight loss, and degree of bonding within the composite. These relationships are used to develop a process window to ensure product quality. The process parameters are then optimized to reduce the lay-up time.
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