New process optimization framework for laser assisted tape winding of composite pressure vessels: Controlling the unsteady bonding temperature

This paper presents an effective process optimization methodology for laser assisted tape winding (LATW) of complex part geometries by means of a numerical optical-thermal model. A winding path on the cylindrical and ellipsoidal (dome) part of a pressure vessel is considered with varying tooling curvature. First, the process model output is verified with the literature data based on the laser intensity distribution. Then, the transient laser irradiation and temperature distributions on the tape and substrate are described comprehensively. It is shown that the maximum laser intensity increases approximately by 80% and the process (bonding) temperature changes by 80 °C at the intersection of the cylindrical and dome section of the pressure vessel. In order to keep the transient process temperature constant, a robust optimization scheme is utilized by means of a genetic algorithm. The design variable is determined as the total laser power and temperature constraints are defined. The proposed optimization methodology regulates the temperature within 1.5 °C variation with respect to the desired value. In order to compensate the transient local curvature effects on the process temperature, the total laser power varies approximately between 30% and 175% of the reference (non-optimized) case. [Display omitted] •Temperature variation in laser assisted tape winding/placement(LATW/LATP) processes should be avoided.•Local changes in the tooling curvature affect the process temperature significantly (up to 30%) in LATW and LATP processes.•New process optimization framework is developed based on the optical-thermal process model.•The unsteady process temperature is kept within the desired temperature limits by optimizing the total laser power.•Proposed physics based process model and the process optimization can be applied to any kind of pressure vessel geometries.