Criteria for selecting cure cycles in autoclave processing of graphite/epoxy composites

Room temperature mechanical properties, such as flexural strength and impact resistance, of epoxies and graphite/epoxy composites go through a maximum as a function of epoxy conversion. For tetraglycidyl 4,4′-diaminodiphenylmethane (TGDDM)-4,4′-diamlnodiphenylsulfone (DDS) formulations, the recommended cure cycle prescribes a maximum temperature close to 177°C. The maximum extent of reaction that may be obtained at this temperature is determined from the vitrification curve. At this maximum conversion, balanced mechanical and physical properties are attained in the partially cured specimen. However, if the standard cycle is used to cure thick parts, the maximum temperature inside the sample increases beyond 177°C. This leads to a complete conversion in most of the part and a consequent impairment of resulting physical and mechanical properties. It is shown how numerical solutions of differential energy and mass balances may be used to propose alternative cure cycles such that the maximum conversion at every point remains bounded by the vitrification curve. An illustration for a particular thickness is provided.