Prepreg control

Evolving from efforts [22] to use the best features of trial-and-error, process model, expert system, and expert model approaches, QPA [23-25] combines KBES traits with online dielectric, pressure, and temperature data to implement autoclave curing control. QPA combines extensive sensor data with KBES rules to determine control actions. These rules determine curing progress based upon process feedback, and implement control action. QPA adjusts production parameters on-line as such—within the limits of its heuristics—QPA can accommodate batch-to-batch prepreg variations. 

Perry and Lee [28,29] offer an enhancement of QPA, based upon use of dual heat flux sensors and additional thermocouples in autoclave curing. This enhancement entails determining heat transfer properties during the cure, then using these properties in conjunction with PID regulatory control of autoclave temperature. Using the additional sensors, Perry and Lee employ an on-line Damkohler number in lieu of the second time-derivative of temperature to avoid exothermic thermal runaway within the prepreg stack thermoset resin. The Damkohler number is defined as ... 

Thorfinnson, B., Biermann, T.F. Measurement and Control of Prepreg Impregnation for Elimination of Porosity in Composite Parts, Society of Manufacturing Engineers, Fabricating Composites 88, Anaheim, September 1988... 

The function of the resin matrix material in filament-wound structures is to help distribute the load, maintain proper fiber position, control composite mechanical and chemical properties, and provide interlaminar shear strength. Either a thermosetting or a thermoplastic resin material may be selected. Thermosetting resins may be selected for application in a wetwinding process or as part of a prepreg resin system. 

The prepreg winding technique offers better control of fiber volume fraction, but at a cost. Material costs are 1.5 to 2 times higher, and there are additional costs associated with storing the preimpregnated (thermosetting matrix) tows. Preimpregnated tows are used almost exclusively for thermoplastic matrix materials, where there are no shelf-life restrictions. 

The chapter is divided into a section on development of process cycles or plans and a section on in-process control. The tools to be discussed include design of experiments, expert systems, models, neural networks, and a variety of combinations of these techniques. The processes to be discussed include injection molding, resin transfer molding, autoclave curing, and prepreg manufacturing. The relative cost and difficulty of developing tools for these applications will be discussed where data is available. 

In Table 15.3 are shown the chemical structures and Tg and of some representative thermoplastic polymers for use at high temperature (3,9). These matrices have high continuous service temperatures (120-200° C) even under wet environmental conditions. Advantages of thermoplastic over thermoset matrices are their shorter fabrication cycle (generally controlled environment storage is not required) and the possibility to be reprocessed and reconsolidated after manufacture. Poly(ether ether ketone) is a strong contender with epoxy resins for use as a matrix in composite prepregs with carbon fibers to be utilized in structural aircraft components. 

The objective of this work has been to generate films, tapes or ribbons which might serve as a prepreg from blends of either an Ultem or a PEEK or a high molecular weight PPS with various liquid crystalline polymers, to identify the parameters that control the formation of reinforcing microfibrils of LCP phase, and to study the mechanical properties of the composite films. 

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