High Energy Electron Beam Curable Resins and Composite Systems

Curing of fiber-reinforced polymer composites using high energy electron beams (HEEB) offers impressive advantages for the fabrication of thick-section composite materials for vehicle structures and ballistic armor protection. HEEB curing greatly reduces the time to cross-link the polymer matrix, while increasing composite tensile strength. The process allows curing at room temperature for high throughput and process flexibility. Electron beam curing produces stronger, uniform composites with reduced voids and stress concentrations. Science Research Laboratory (SRL) has developed a new generation of pulsed linear induction accelerators which allow reliable, cost efficient production of high average power electron beams with the necessary parameters for high energy electron beam curing of advanced composites. Unique features of these accelerators include high repetition rate (> 5000 pps), all-solid-state pulsed-power drivers which make these accelerators scalable to megawatt power levels at a capital cost for the accelerator of less than $3/Watt. SRL has assembled a three-way collaboration to develop and test new electron-beam curable resins for primary structural composite applications. The team includes two resin-material suppliers, personnel at the University of Delaware Center for Composite Materials (CCM) and SRL. The results of Phase I experiments will determine the properties of several novel resin formulations, fiber sizings and electron beam curing parameters on composite material properties. The Phase I results will allow fabrication of prototype vehicle structures with optimized mechanical properties during Phase II.