BEST PRACTICES: OUT OF AUTOCLAVE PREPREGS

IBEX 2013, September 17

D. Michael Bergen, Custom Technologies LLC David Jones, DE Jones & Associates

ADVANTAGES: NAVY PERSPECTIVE

Current technology for naval structures is based on VARTM process
Drawback to VARTM is the inability for full infusion wet-out on large scale and/or thick parts (DDG-1000 deck house is about 700tons of carbon composite)
primary focus of university funded research
Material handling on vertical surfaces & hull sides complicate the ability to scale VARTM successfully
OOA prepreg eliminates the critical weaknesses of VARTM:
spray tack, a proven contaminant
most race tracking resin deprivation
laminate vacuum lock
maintains full atmosphere of vacuum under the bag (better consolidation)
eliminates the need for complex ow models and monitoring systems
Incorporate complex features in initial laminate

Full vacuum Atmospheric pressure behind front

Basic VARTM Layout

FLIPPING DDG 1000 DECK HOUSE

Photo Courtesy Huntington Ingalls

DDG 100 DECK HOUSE NEARING COMPLETION

Photo Courtesy Huntington Ingalls

DECKHOUSE ROLL OUT

Photo Courtesy Huntington Ingalls

SPECIFIC ADVANTAGES
The OOA prepreg fabrication system also provides specic:
Fiber volume fraction & resin to ber ratio
resulting in the ability to maintain critical dimensions and strength in complex cross-sections
Co-curing of the inner & outer skin to core
no need to hot coat the core
more effective structure with negligible resin migration into the core
the former provides the additional benets of labor reduction through process reduction
More accurate laminate placement for focused structural requirements (tooling as well as hull / superstructure)
Successful cures in prepreg laminates up to 2.5 thickness

SPECIFIC ADVANTAGES CONT.

Longer working times for lamination (measured in weeks)
Include complex features that VARTM cannot due to inability to reverse ow
Ability to achieve autoclave quality with proper laminating practice
Loss of vacuum do not necessarily lose the part (oven off, x bag)
Less recurring material waste
Much cleaner shop environment
Happy workers (get to work in A/C)
No VOC
No HAZMAT, resin is already polymerized (non-hazardous warehouse)

TOOLING

TOOLING CONT.
Advantages
Matched CTE for post curing
Excellent strength & stiffness
Thinner tools is less mass to heat during curing cycles
Requires less backing structure and is lighter
Lower void content
Less issues at elevated temperatures
Potentially less porosity relating to vacuum integrity
Dimensional stability is key element
Tighter tolerances when producing multiple parts which come together
Speed of construction based on laminate design
Much cleaner than wet laminate construction

NO SPRAY TACK

MAINTAIN CRITICAL DIMENSIONS

CRITICAL DIMENSIONS CONT.

CRITICAL DIMENSIONS CONT.

INCORPORATE COMPLEX FEATURES

DISADVANTAGES
Post curing phobias, especially in large structures
need large oven for large production parts
Perception of limited resin choices
Intermediate de-bulking steps
Requires different skill set
May be labor intensive (placement and hand consolidation)
Cold storage
Lead times for materials, especially recovering from errors
Initial cost of material
Needs A/C work environment
control tack
moisture contaminates parts (condensation or sweat)