Abstract
We report a composite capable of advanced manufacturing and damage repair. Microwave energy is used to induce thermal reversible polymerization of the matrix allowing for microwave assisted composite welding and repair. Composites can be bonded together in just a few minutes through microwave welding. Lap shear testing demonstrates that microwave welded composites exhibit 40% bond strength relative to composites bonded with epoxy resin. Double cantilever beam testing shows 60% recovery in delamination strength after microwave assisted composite repair. The interfacial adhesion and composite repair after microwave exposure are examined by X-ray computed tomography. The microwave processing is shown to be reproducible and consistent. The ability to perform scalable manufacturing is demonstrated by the construction of a large structure from smaller components.
Highlights
Composites offer an immense potential for reducing energy expenditure during the operation of systems composed of these materials due to their light weight
Composite panels were inspected by X-ray computed tomography (CT) to detect whether any defects or damage was induced by the cutting of panels
It is possible that prestress exists within the composites during microwave welding, most likely at defect sites associated with manufacturing or machining of the composite structure
Summary
Composites offer an immense potential for reducing energy expenditure during the operation of systems composed of these materials due to their light weight. Conventional heating methods used for the production of composites can drive up manufacturing cost as a result of the inefficient heat transfer processes involved in the curing of these materials. Microwave processing can provide more effective and efficient curing, thereby leading to a reduction in the time and cost of composite manufacturing. Another promising capability of microwaves is their potential use for bonding or welding of polymer materials. Polymer composites are generally joined through the use of adhesives or mechanical fasteners These methods can require extensive surface preparation for adhesive bonding and can result in localized stress fields around machined areas necessary for the placement of fasteners. We report preliminary microwave welding experiments on 2MEP4F carbon fiber composites
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