Intelligent processing for thick composites

Manufacturing thick composite parts are associated with adverse curing conditions such as large in-plane temperature gradient and exotherms. The condition is further aggravated because the manufacturer's cycle and the existing cure control systems do not adequately counter such affects. In response, the forecast-based thermal control system is developed to have better cure control for thick composites.; Accurate cure kinetic model is crucial for correctly identifying the amount of heat generated for composite process simulation. A new technique for identifying cure parameters for Hercules AS4/3502 prepreg is presented by normalizing the DSC data.; The cure kinetics is based on an autocatalytic model for the proposed method, which uses dynamic and isothermal DSC data to determine its parameters. Existing models are also used to determine kinetic parameters but rendered inadequate because of the material's temperature dependent final degree of cure. The model predictions determined from the new technique showed good agreement to both isothermal and dynamic DSC data. The final degree of cure was also in good agreement with experimental data.; A realistic cure simulation model including bleeder ply analysis and compaction is validated with Hercules AS4/3501-6 based laminates. The nonsymmetrical temperature distribution resulting from the presence of bleeder plies agreed well to the model prediction. Some of the discrepancies in the predicted compaction behavior were attributed to inaccurate viscosity and permeability models. The temperature prediction was quite good for the 3cm laminate.; The validated process simulation model along with cure kinetics model for AS4/3502 prepreg were integrated into the thermal control system. The 3cm Hercules AS4/3501-6 and AS4/3502 laminate were fabricated. The resulting cure cycles satisfied all imposed requirements by minimizing exotherms and temperature gradient. Although the duration of the cure cycles increased, such phenomena was inevitable since longer time was required to maintain acceptable temperature gradient. The derived cure cycles were slightly different than what was anticipated by the offline simulation. Nevertheless, the system adapted to unanticipated events to satisfy the cure requirements.