Advanced Composites Research to Reduce Cost (MSC P6016)

The high manufacturing success rate achieved in the fabrication of glass fabric laminates and sandwich constructions using the Vacuum Assisted Resin Transfer molding (VARTM) process has not been duplicated for carbon fabric parts due to the slower, more complex flow processes that occur in carbon fabrics. Part reject rates have been high due to the presence of significant void concentrations and/or balsa to laminate interface disbonds. The goal of the STTR program outlined in this proposal is to demonstrate that intelligent infusion methods utilizing infusion modeling and infusion flow sensor technologies will result in consistently produced, high quality carbon laminates and sandwich structures. This STTR program is focused on determining and demonstrating advancements to existing flow modeling capabilities and resin sensor technologies to enable their utilization in large parts, with (conductive) carbon fabrics, and in humid, temperature-variable infusion environments; and transitioning these capabilities and technologies for routine use on the shop floor. BENEFITS: Development and implementation of the proposed technology will significantly reduce scrap rates of large, resin-infused carbon fabric parts resulting in significant labor and materials cost savings. The developed technology has application to commercial shipbuilding, recreational marine craft, wind turbine blades, sports equipment, and other commercial applications of carbon fabric.