Cure Cycle Optimization of Rapidly Cured Out-Of-Autoclave Composites

Autoclave process parameters affecting mechanical and thermomechanical properties of CFRP laminates using response surface methodology

Autoclave curing is a manufacturing process for high-performance parts based on carbon fiber–reinforced polymers (CFRPs) used for large aircraft parts. Today, this manufacturing process is the reference in terms of quality and, therefore, the manufactured parts’ mechanical performance and robustness. However, several parameters can impact the quality of the parts resulting from this process, which requires optimizing key manufacturing parameters. In this study, the effect of autoclave process parameters (i.e., temperature, pressure, and vacuum-pressure) on the glass transition temperature (Tg), laminate compressive modulus (LCM), laminate compressive strength (LCS), and interlaminar shear strength (ILSS) was investigated using three factors, three-level Box–Behnken design (BBD) and response surface methodology (RSM). In addition, the interactions of processing parameters with Tg, LCM, LCS, and ILSS were investigated, making this study an essential investigation for accurately selecting processing parameters. Thus, there is a functionally non-linear relationship between the interaction of the autoclave process parameters. Therefore, these parameters were optimized using RSM with the maximum Tg, LCM, LCS, and ILSS. The optimization and validation of the obtained models were carried out with an average relative error below 3% for all thermomechanical and mechanical properties, indicating that the BBD and optimization were correct. Because of this, the established regression models can accurately predict the Tg, LCM, LCS, and ILSS in autoclaved epoxy/carbon composite laminates.

Reuse of Carbon Fibers and a Mechanically Recycled CFRP as Rod-like Fillers for New Composites: Optimization and Process Development

The rising amount of carbon fiber reinforced polymer (CFRP) composite waste requires new processes for reintroducing waste into the production cycle. In the present research, the objective is the design and study of a reuse process for carbon fibers and CFRP by mechanical recycling consisting of length and width reduction, obtaining rods and reintegrating them as fillers into a polymeric matrix. Preliminary studies are carried out with continuous and discontinuous unidirectional fibers of various lengths. The processing conditions are then optimized, including the length of the reinforcement, the need for a plasma surface treatment and/or for resin post-curing. The resin is thermally characterized by differential scanning calorimetry (DSC), while the composites are mechanically characterized by tensile strength tests, completed by a factorial design. In addition, the composites tested are observed by scanning electron microscopy (SEM) to study the fracture mechanics. Optimal processing conditions have been found to reduce the reinforcement length to 40 mm while maintaining the mechanical properties of continuous reinforcement. Furthermore, the post-curing of the epoxy resin used as matrix is required, but a low-pressure plasma treatment (LPPT) is not recommended on the reinforcement.

A Review on the Out-of-Autoclave Process for Composite Manufacturing

Composite materials have gained increased usage due to their unique characteristic of a high-stiffness-to-weight ratio. High-performing composite materials are produced in the autoclave by applying elevated pressure and temperature. However, the process is characterized by numerous disadvantages, such as long cycle time, massive investment, costly tooling, and excessive energy consumption. As a result, composite manufacturers seek a cheap alternative to reduce cost and increase productivity. The out-of-autoclave (OoA) process manufactures composites by applying vacuum, pressure, and heat outside of the autoclave. This review discusses the common out-of-autoclave processes for various applications. The theoretical and practical merits and demerits are presented, and areas for future research are discussed.

Analysis of Composite Structures in Curing Process for Shape Deformations and Shear Stress: Basis for Advanced Optimization

Identifying residual stresses and the distortions in composite structures during the curing process plays a vital role in coming up with necessary compensations in the dimensions of mold or prototypes and having precise and optimized parts for the manufacturing and assembly of composite structures. This paper presents an investigation into process-induced shape deformations in composite parts and structures, as well as a comparison of the analysis results to finalize design parameters with a minimum of deformation. A Latin hypercube sampling (LHS) method was used to generate the required random points of the input variables. These variables were then executed with the Ansys Composite Cure Simulation (ACCS) tool, which is an advanced tool used to find stress and distortion values using a three-step analysis, including Ansys Composite PrepPost, transient thermal analysis, and static structural analysis. The deformation results were further utilized to find an optimum design to manufacture a complex composite structure with the compensated dimensions. The simulation results of the ACCS tool are expected to be used by common optimization techniques to finalize a prototype design so that it can reduce common manufacturing errors like warpage, spring-in, and distortion.

Effects of Processing Parameters for Vacuum-Bagging-Only Method on Shape Conformation of Laminated Composites

Complex composite structures manufactured using a low-pressure vacuum bag-only (VBO) method are more susceptible to defects than flat laminates because of the presence of complex compaction conditions at corners. This study investigates the contribution of multivariate processing parameters such as bagging techniques, curing profiles, and laminate structures on laminates’ shape conformation. Nine sets of laminates were produced with a concave corner and another nine sets with a convex corner, both with a 45° inclined structure. Three-way analysis of variance (ANOVA) was performed to quantify thickness variation and spring effect of laminated composites. The analysis for concave and convex corners showed that the bagging techniques is the main factor in controlling the laminate thickness for complex shape applications. The modified (single) vacuum-bag-only (MSVB) technique appeared to be superior when compared to other bagging techniques, exhibiting the least coefficients of variation of 0.015 and 0.016 in composites with concave and convex corners, respectively. Curing profiles and their interaction with bagging techniques showed no statistical significance in the contribution toward laminate thickness variation. The spring effect of laminated composites was investigated by calculating the coefficient of determination (R2) relative to that of the mold. The specimens exhibited a good agreement with R2 values ranging from 0.9824 to 0.9946, with no major data offset. This study provides guidelines to reduce thickness variations and spring effect in laminated composites with complex shapes by the optimum selection of processing parameters for prepreg processing.

Research on Temperature Field Distribution in a Frame Mold during Autoclave Process

The success of an autoclave process is related to the temperature characteristics of the mold. An inhomogeneous temperature field in the mold affects the quality of composite parts, which may lead to residual stress, voids, and other manufacturing defects of composite parts. In order to meet high-quality production demands, the temperature field in a mold should be investigated precisely. The temperature distribution in a large frame mold is critically evaluated in this work. Then, a method to control the temperature distribution in a large frame mold is proposed. A computational fluid dynamics (CFD) model of the autoclave process is developed to predict the temperature evolution of the large frame mold. The model is validated by experimental results, which shows good agreement with a relative difference of 5.92%. The validated CFD model is then applied to analyze the temperature distribution characters in the mold with different control conditions. The results show that the temperature difference decreases by 13.3% when the mold placement angle is changed from 180 to 168°.

Study of the Degree of Cure through Thermal Analysis and Raman Spectroscopy in Composite-Forming Processes

The curing of composite materials is one of the parameters that most affects their mechanical behavior. The inspection methods used do not always allow a correct characterization of the curing state of the thermosetting resins. In this work, Raman spectroscopy technology is used for measuring the degree of cure. The results are compared with conventional thermal gravimetric analysis (TGA), differential scanning calorimetry (DSC), and scanning electron microscope (SEM). Carbon fiber specimens manufactured with technologies out of autoclave (OoA) have been used, with an epoxy system Prepreg System, SE 84LV. The results obtained with Raman technology show that it is possible to verify the degree of polymerization, and the information is complementary from classical thermal characterization techniques such as TGA and DSC; thus, it is possible to have greater control in curing and improving the quality of the manufactured parts.