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Yohann Ledru
Abstract
Voids in aeronautical composite laminates
Yohann Ledru - 14 December 2009
Long fiber reinforced epoxy matrix composite laminate manufacturing process is divided into several stages. The most critical one is the polymerization stage. If not optimized, defects in the bulk material such as voids can occur. The aim of this work is to investigate the void formation and evolution processes in order to improve the thermoset laminates quality in minimizing the void ratio. Two phenomena causing void formation have been identified. The first is the mechanical entrapment of gas bubbles between prepreg plies during the lay up. Second is a thermodynamical one. Solvents and humidity absorbed by the prepreg during its manufacturing can be evaporated by increasing the temperature. Then, it has been shown that the vaccum bag lay up permeability in combination with the vaccum pressure could favour the gas washing out. In parallel, thermo-mechanical and diffusion models are coupled to obtain an accurate void size prediction along temperature and pressure applied during the polymerisation. In fact, these two parameters induce variations of the gas bubble radius inside resin. The first experimental results seem to validate qualitatively the calculated void size behaviour. Indeed, hydrostatic pressure imposed during polymerization plays a very important role on gas bubble shrinkage. Finally, a new experimental setup using image analyses has been developed to measure as accurate as possible the volume void ratio. Under specific conditions, stereology allows to extrapolate 2D results to 3D ones. Void ratios obtained with this method are in good agreement with acid digestion results. Complementary morphometric studies on void shapes have given new information about the heterogeneous void distribution in the specimen and also on the statistical void size distribution versus polymerization conditions.
Key words:
composite materials, prepreg, void, modeling, image analyses ,
diffusion.
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