Low-Cost Microwave Curing of Aerospace Composite Materials

The Navy requires a low-cost, industrial electromagnetic heating system for curing composite materials. The goal of this Phase II STTR is to develop a multi-physics simulation model with associated electromagnetic heating applicator which will allow the Navy to both predict and design production cure cycles for CFRP composite parts. The approach taken is to characterize the anistropic electrical and chemical material properties of CFRP composite materials at low microwave power and build a multi-physics software module for integration with commercial FEA. Preliminary results from the Phase I base program show good correlation between simulation and the measured response of CFRP materials radiated by microwave energy. PSI will design and build a corresponding electromagnetic applicator that uses low-cost electromagnetic sources and can be installed in heritage autoclaves for curing large aerospace composite parts. This technology has the potential to improve cured mechanical properties, and significantly reduce the autoclave cure cycle time and overall energy expense. During Phase II, PSI will use the multi-physics model to design the cure cycle for a CFRP production part, and demonstrate curing the part in an autoclave. Data from these tests will be used to market the multi-physics model and electromagnetic applicator for Phase III funding.