Smart Manufacturing Methods for Carbon/Vinyl Ester Structures

摘要

The US Navy is aggressively pursuing larger components constructed using fiber-reinforced plastic or composite materials. However, the overall processes involved in manufacturing high-strength low weight composite components are still relatively new to US Navy shipbuilders. Vacuum Assisted Resin Transfer Molding (VARTM) a common composite fabrication methodology for composite structures is extremely sensitive to the material systems used and the production set-up or design. Any infusion-related defects easily lead to significant rework costs and schedule interruptions. Focusing on the DDG 1000 composite deckhouse and hangar the objective of this project was to develop a resin infusion process for each of two carbon fiber/vinyl ester resin composite joints that is predictable repeatable and reduces the defect rate experienced with current processes. Two common types of DDG 1000 composite deckhouse joints were examined in this project. Computer software was used to model and analyze the proposed VARTM infusion process designs yielding optimized composite panel joint infusion processes. Resin flow sensors were installed in each joint and were used to monitor resin flow fronts for the VARTM infusions. Non-Destructive evaluation of test specimens was performed to identify any potential defects in the test articles produced and also validate the computer models.