Publications

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The moisture absorption behavior of two fiber reinforced composite materials was evaluated in a unidirectional manner The flat materials were exposed to varying humidity and temperature conditions inside of an environmental chamber in order to determine their effective moisture equilibrium (M m ) and moisture absorption rate (D z ). Two-ply (thin) and four-ply (thick) materials were utilized to obtain M,,, and Dz, respectively. The results obtained from laboratory work were then compared to modeling data to better understand the material properties. Predictions capabilities were built to forecast the maximum moisture content, time required for saturation, and the moisture content at any given humidity and temperature. A case study was included to demonstrate this capability. Also of interest were cubed samples to investigate directionality preferences in water immersion studies. Several coatings were evaluated for their water permeation properties. Further dissemination authorized to the Department of Energy and DOE contractors only; other requests shall be approved by the originating facility or higher DOE programmatic authority.

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The kinetics of thermoset resin cure are multifaceted, with flow and wet-out being dependent on viscosity, devolatilization being a function of partial pressures, and crosslinking being dependent on temperature. A unique cure recipe must be developed to address and control each factor simultaneously. In the case of thick-section composites, an uncontrolled exotherm could cause the panel to cure from the inside out, causing severe process-induced residual stresses. To identify and control the peak heat generation from the exothermic crosslinking reaction, differential scanning calorimetry (DSC) was conducted for different candidate cure schedules. Resin rheology data and dynamic mechanical analysis (DMA) results were used to confirm a viable resin viscosity profile for each cure schedule. These experiments showed which isothermal holds and ramp rates best served to decrease the exothermic peak as well as when to apply pressure and vent the applied vacuum. From these data, a cure cycle was developed and applied to the material system. During cure, embedded thermocouples were used to monitor heat generation and drive cure temperature ramps and dwells. Ultrasonic testing and visual inspection by microscopy revealed good compaction and < 1 % porosity for two different composite panels with the same resin system. DSC of post-cured samples of each panel indicated a high degree of cure throughout the thickness of the panels, further qualifying the proven-in process.

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