Microwave and conventional curing of thick-section thermoset composite laminates: Experiment and simulation

In conventional processing, thermal gradients cause differential curing of thick laminates and undesirable outside-in solidification. To reduce thermal gradients, thick laminates are processed at lower cure temperatures and heated with slow heating rates, resulting in excessive cure times. Microwaves can transmit energy volumetrically and instantaneously through direct interaction of materials with applied electromagnetic fields, The more efficient energy transfer of microwaves can alleviate the problems associated with differential curing, and the preferred inside-out solidification can be obtained. In this work, both microwave curing and thermal curing of 24.5 mm (1 inch) thick-section glass/epoxy laminates are investigated through the development of a numerical process simulation and conducting experiments in processing thick laminates in a conventional autoclave and a microwave furnace. Outside-in curing of the autoclave-processed laminate resulted in visible matrix cracks, while cracks were not visible in the microwave-processed laminate. Both numerical and experimental results show that volumetric heating due to microwaves promotes an inside-out cure and can dramatically reduce the overall processing time.