Compactibility and Fibre Volume Fraction Limits of Unidirectional Discontinuous Carbon Fibre Thermoset Prepreg Laminates

The aim of this study was to explore the compactibility of unidirectional staple carbon fibre laminates in comparison with their uni- and biaxial continuous fibre counterparts. Resin-preimpregnated plies were inserted into a heated compression mould at an elevated mould temperature of 110 °C. By applying stepwise loading, the correlation between consolidation pressure and fibre volume content was derived and related to fibre orientation distribution. The fibre orientation distribution is obtained from photographic image analyses of 2D ply sections of the same samples using the structure tensor approach. For commonly used autoclave prepreg pressure of 6.8 bar results indicate that lower-oriented staple carbon fibre unidirectional laminates with a fibre orientation distribution factor η0 = 0.74 can potentially reach a maximum of 39% fibre volume fraction, while higher-oriented laminates with η0 = 0.78 end up at 43%. An exponential extrapolation suggests that a consolidation pressure of ≥90 bar is required to achieve 60% fibre volume content with highly oriented unidirectional staple carbon fibre laminates.