Viscoelastic properties of polymer composites during processing

Residual stresses that are induced during processing of polymer matrix composites lead to warpage of structural parts and can produce microcracks and other forms of damage. Process models that track the development of residual stresses in composites during processing have received growing attention in recent years. An accurate and easy to implement simulation will help lower the manufacturing cost by enabling engineers to predict and prevent the warpage in parts due to residual stress. The critical feature of a process model is the development of an accurate material model to predict mechanical properties throughout the entire manufacturing cycle. Material models are very complex since the matrix changes from a fluid to a viscoelastic solid at the end of cure.; In this work several aspects of the curing, viscoelastic, and cure shrinkage behavior of an aerospace grade epoxy resin were characterized and modeled for the purpose of composites process modeling. Measurement of matrix viscoelastic properties during cure was accomplished through two experimental approaches, each suited to a particular range of cure states. To investigate the material behavior during later stages of cure after gelation, small beam specimens were tested in three-point bending. During early stages of curing, samples were examined by shearing the material between parallel plates in a rheometer. Specimens for each configuration were manufactured at several cure states and tested at a range of temperatures. These data were used to develop a material model to predict the relaxation modulus of the matrix at any time during cure. Additionally, moiré interferometry was successfully applied to the measurement of the viscoelastic Poisson's ratio of the matrix through its entire glassy-to-rubbery transition. The matrix viscoelastic material models were then used to predict composite viscoelastic properties and correlated with experimental results. In addition, the viscoelastic shrinkage behavior of the composite during cure was investigated with micromechanical modeling.