Innovative Resin for Non-Autoclave Resin Film Infusion Composites Repair

Composite parts on aircraft can be field repaired if the damage is small, using only vacuum and heat blankets or portable ovens. As alternative to using wet laminating resins and prepreg systems for repair, resin film infusion (RFI) is cost effective and can alleviate some problems with current repair methods. In Phase I, RFI resin films were developed that have a shelf-life greater than one year at ambient conditions. These resin films were developed in many different areal weights and were vacuum encapsulated for long-term storage. This approach provides a film or films that can be selected according to the fiber preform weight and cut to shape depending on the repair dimensions. Also, a methodology was developed for processing the RFI resin films that results in void free composites having excellent mechanical properties. Phase II will focus on demonstrating this technology and refining the methodology for composite repair applications using specific test parts and combinations of different materials and fabric preforms. A comprehensive study will be performed to understand the relationship between the processing variables and the mechanical performance of the repaired composite.