Variable frequency microwave (VFM) curing, processing of thermoset prepreg laminates. Final report

The objective of this work was to investigate the beneficial effect of the variable frequency microwave (VFM) technology to cure thermosetting prepreg laminates. Further, it was to investigate the interrelationship and effect on the curing process of frequency, band width, and curing time with different types of laminates. Previous studies of microwave-assisted curing of neat resins (epoxy) and unidirectional glass and carbon fiber laminates with a fixed frequency of 2.45 GHz, have shown that a substantial reduction in the curing time was obtained. Results of this earlier work indicate that the microwave-assisted curing of multidirectional glass fiber laminates also show a substantial reduction of the required curing time. This may be explained by the penetration of microwave energy directly and throughout the laminate with enhancement of the kinetics of the chemical reaction. The fixed frequency microwave radiation of 2.45 GHz has been demonstrated to be a partially acceptable method to cure unidirectional carbon fiber laminates. Multidirectional carbon fiber/epoxy laminates demonstrate a lack of coupling during the curing process. A direct curing of these laminates was not possible by microwave radiation with the experimental approach used in agreement with previous work. In addition to this short coming, the unidirectional laminate samples cured with the fixed frequency are visually nonuniform. Localized areas of darker colors (burn, hot spots, overheating) are attributed to the formation of standing waves within the microwave cavity. For this reason, the laminates are subject to proper rotation while curing through fixed frequency. The present research indicates that variable frequency microwave technology is a sound and acceptable processing method to effectively cure uni-, bi- or multi-directional thermosetting glass fiber laminates. Also, this methodology will effectively cure unidirectional thermosetting carbon fiber laminates. For all these cases, this technology yielded a substantial reduction in the required cure time of these laminates. Multidirectional carbon fiber laminates demonstrated a lack of coupling of VFM energy during the curing process