A MODEL BASED ACCELERATED RTM PROCESS DESIGN FOR OPTIMAL PERFORMANCE

Typical CFRP composite high-rate manufacturing processes require a multi-physics understanding of the key material and process design variables. A model-based approach may deliver an optimized manufacturing process and yet require experimental validation of quality and mechanical performance to make it an acceptable solution to the industry. This study captures a multi-physics model-based development of an accelerated RTM process design for low permeability fiber reinforcement, while delivering laminates that meet the specifications on quality and key mechanical properties. Hexcel’s biaxial IM8 HiMax® non crimp fabric with a thermoplastic veil and 1078-1 resin is chosen for the study to develop a process design methodology for (177 °C) cure epoxy. Multi-physics material models of IM8 HiMax® and 1078-1 resin are used to simulate and predict the optimum cure cycles. Critical mechanical testing compares the outcomes from different cure cycles, including a baseline process nominally followed by the industry. Results show that the accelerated cured panels (50% cycle time compared to the baseline) are of good quality and perform just as well for the mechanical properties. This model-based approach can be extended to more complex geometry and structures for this material system or applied to additional composite material systems.