Porosity-Free Molded Surfaces for Out-of-Autoclave (OoA) Composites

ABSTRACT: The objective of this project is to demonstrate an innovative approach to mold preparation materials and/or processes for vacuum-bag-only composite processing. We will identify the mechanism that causes surface pitting and then develop a novel mold release for overcoming this issue in the preparation of Out-of-Autoclave composites. Preliminary experiments will be performed to demonstrate the potential of the new nonstick materials on a mold release Al tool. An OoA carbon/epoxy fabric prepreg, such as T650-35/5320-1 8HS fabric, will be laid up and cured in the Al tool, yielding initial results that show promise for eliminating surface pitting on the finished composite. BENEFIT: Commercialization of an effective mold release technology for producing Out-of-Autoclave (OoA) composites with smooth surface finishes will be a major advancement in aerospace manufacturing technology. It will produce aircraft structures that are lighter weight and with higher performance aerodynamics. This will solve a major problem with OoA manufacturing technology, and will accelerate its widespread use by the aerospace industry. The anticipate benefit will be much lower cost and higher performance aircraft for both commercial and military applications.