Microwave Curing Process Modeling for Continuous Carbon Fiber Reinforced Thermoset Composites

The NAVY seeks microwave curing process modeling and technology demonstration for the cost-effective fabrication of continuous carbon fiber reinforced thermoset composites with reduced cure time and energy consumption. Despite the relatively extensive research work done for the microwave curing of polymer composites, the technology extension for the fabrication of continuous carbon fiber-reinforced thermoset composites (CFRTCs) is challenging to retain the uniform temperature during the curing and eliminate the local heat source-induced damage in the cured parts. To demonstrate the feasibility of manufacturing high-quality CFRTC using microwave radiation with performance-informed process parameters, Global Engineering and Materials, Inc. and collaborators propose to develop a multi-physics modeling approach to simulate the microwave curing process of CFRTC coupons of different thicknesses and layups by including 1) the interaction of electromagnetic, thermal, and chemical mechanisms during the curing; 2) micro-macro coupling to capture the local heat generation and determine the effective modeling parameters for the global curing model; 3) a close loop with the data collected from the in-situ sensor to achieve the desired temperature history within the part; and 4) thermo-mechanical coupling for the residual stress and distortion prediction. In Phase I, the research team will use two materials of CFRTC and fabricate the coupons using the conventional autoclave and microwave curing procedures. A comparative study will be performed based on tensile, flexural, and non-destructive tests to demonstrate the performance and benefits of using the process tailoring of the microwave curing process.