The use of X-ray computed tomography for design and process modeling of aerospace composites: A review

Abstract Optimization of process parameters of major aerospace composites manufacturing techniques is essential for manufacturing high-quality aerospace components. However, studying many parameters through experimental approaches is time-consuming and labor-intensive. Modern X-ray Computed Tomography (XCT) technology has made it possible to monitor the complete manufacturing process “in-situ,” due to its high spatial resolution and very short acquisition time. The scanned data can then be used to generate numerical models for predicting different process parameters. This article presents a comprehensive review of the design and modeling aspects of key aerospace composites manufacturing techniques using the XCT procedure. Key functioning of XCT is reviewed with a view to adopt several modeling approaches ranging from mesoscale to macro-scale models for composites processing. The XCT machine parameters during image acquisition and post-processing determine the accuracy and computation time, which are also discussed in detail. The applications of XCT-based material models are reviewed for process characterization of autoclave and out-of-autoclave manufacturing. Current aerospace manufacturing characterization techniques, combined with advanced modeling approaches using XCT and CFD tools, show great potential for designing modern material models that will help in the design of better manufacturing processes for next generation aerospace parts.