Technologies for the Rapid Curing of Composite Parts

Polymer-matrix composite parts are routinely fabricated using long autoclave cure cycles.  The total time of the curing process is primarily driven by the ability to heat up and cool down the part/tool.  The current autoclave cycle times can result in increased capital expenditures for programs with high build rates.  For simpler smaller size parts produced in high volumes it is desirable to move toward manufacturing cure processes that would reduce the requirement for autoclaves, and at the same time reduce the manufacturing cost of those articles. The objective of this project is to develop and demonstrate the use of the Quickstep process for rapidly curing IM-7 carbon fiber fabric preimpregnated with 5250-4 BMI resin.  The program will demonstrate the resulting cure cycle using the Quickstep process will provide the same laminate physical and mechanical properties as the traditional autoclave process.  Further, the developed curing process will demonstrate capability to be scaled for parts such as long spars, blade seals and moderately complex contoured fairings. BENEFIT: The development of rapid curing processes for BMI resins can have significant benefits for the cost of some small, high volume aircraft parts. By removing this type of part family from already overloaded autoclave cure schedules, will significantly impact overall manufacturing costs. This impact can be seen in several ways including lower cost of energy, lower tooling costs since fewer tools will be required in rate production,  and an increase in turn time of the selected parts. One study completed by a U.K. manufacturer of blocker doors for commercial jet engines estimated a tooling cost savings of approximately 82%, due to a combination of reduced tool sets and lower costs of a Quickstep tool compared to an autoclave or oven tool.