Numerical and Experimental Study of Local Resin Pressure for the Manufacturing of Composite Structures and Their Effect on Porosity

Porosity can have significant impact on the mechanical performance of composite structures. The primary sources of voids during the cure of composites include air entrapped during lay-up, bag or tool leaks, and the off gassing of volatiles. Capturing the physics of void evolution during composite processing is a challenge due to the number of sources and changing phenomena that give rise to voids as the resin cures. Local changes in resin pressure due to geometric features or cure shrinkage have been experimentally linked to a higher likelihood of void formation. In this work, a preliminary model was developed to predict local resin pressure which can be used to identify regions more susceptible to porosity. Experiments were conducted to validate the model accuracy. Ultimately, this model can be used as a tool to minimize the likelihood of porosity by optimizing the material selection, part design, layup, and cure process.