Advanced process simulations for thick-section epoxy powder composite structures

Numerical modelling is used to perform process simulations for thick-section composite laminates. Three forms of laminate are used to illustrate how thermal and cure gradients can be reduced by choice of thermal cycle. Low exotherm epoxy powders with the vacuum bag process have shown success in both glass and carbon fiber systems and the results presented in the present work show how the optimum thermal cycle can be determined. The three laminate geometries investigated in the present study included: a one-dimensional flat laminate, a threedimensional flat laminate, and an axisymmetric section of the cylindrical root of a typical wind turbine blade. Further, energy efficient and cost-effective alternative heating methods are explored.

Automated summary

Numerical modelling is used to simulate the manufacturing process of thick-section composite laminates, and different thermal cycles are explored to reduce thermal and cure gradients. The study shows the successful application of low exotherm epoxy powders and vacuum bag process in glass and carbon fiber systems, and determines the optimum thermal cycle. Additionally, energy efficient and cost-effective alternative heating methods are investigated.