Abstract:
High-performance thermoplastic composites exhibit superior impact resistance compared to traditional thermosetting composites, along with excellent weldability, which is expected to reduce the use of fasteners and thereby achieve better weight reduction for aircraft. Consequently, high-performance thermoplastic composites hold significant potential for future applications in the aviation sector. Among these, polyaryletherketone (PAEK) composites not only exhibit excellent impact toughness but also demonstrate high-temperature resistance, solvent resistance, and fatigue resistance, making them a class of high-performance thermoplastic composites with outstanding comprehensive properties. Early research primarily focused on polyetheretherketone (PEEK) composites and polyetherketoneketone (PEKK) composites. However, PEEK resin has a high melting temperature of 343℃, with a forming temperature reaching up to 390℃. The high forming temperature and pressure of PEEK composites have long hindered their widespread adoption in the aviation industry. In recent years, with the successful development of low-melting-temperature polyaryletherketone (LMPAEK) resins (Tm < 320℃), the processability of PAEK composites has significantly improved, particularly in automated fiber placement (AFP) technology, making it possible to achieve true in-situ consolidation during automated layup. The advancement of automated fiber placement and welding technologies for PAEK composites plays a crucial role in reducing manufacturing costs, improving product consistency, and enabling aircraft weight reduction. These developments are of great significance in promoting the application of PAEK composites in the aviation field. This paper provides a comprehensive review of recent research and application advancements in PAEK composites, AFP technology, welding techniques, and their utilization in the field of aviation.