The aim of this study was to optimize the ultrasonic consolidation (USC) parameters for 'PEI adherend/Prepreg (CF-PEI fabric)/PEI adherend' lap joints. For this purpose, artificial neural network (ANN) simulation was carried out. Two ANNs were trained using an ultra-small data sample, which did not provide acceptable predictive accuracy for the applied simulation methods. To solve this issue, it was proposed to artificially increase the learning sample by including additional data synthesized according to the knowledge and experience of experts. As a result, a relationship between the USC parameters and the functional characteristics of the lap joints was determined. The results of ANN simulation were successfully verified; the developed USC procedures were able to form a laminate with an even regular structure characterized by a minimum number of discontinuities and minimal damage to the consolidated components.
Keywords: PEI; adhesion; carbon fiber fabric; interface; lap joint; machine learning; neural network simulation; prepreg; structural integrity; ultrasonic consolidation.