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1. Introduction Out-of-autoclave (OoA) prepreg processing has been developed as an effective alternative to autoclave cure. While autoclaves use a pressurized environment to suppress voids and mitigate geometric variability [1], OoA processing consists of curing specially designed prepregs using vacuum bag-only (VBO) method, and can provide technical, economic and environmental benefits compared to conventional manufacturing. OoA processing can be used to produce flat laminates with autoclave-level microstructural and geometric quality without difficulty. However, the limited compaction pressure available during manufacturing and the distinctive characteristics of VBO prepregs render the production of parts with complex geometries challenging. The two defects most commonly observed during composites manufacturing are microstructural voids and dimensional non-uniformity. Void content is a primary concern due to its effect on mechanical properties [2-4], and the mechanisms of void formation in prepreg laminates have been studied extensively [4]. It is now widely accepted that gas-induced voids can be caused by absorbed moisture, residual solvents within the resin, and air entrapped between and within prepreg plies [4,5]. Furthermore, flow-induced voids can arise if the resin matrix does not fully saturate the fiber bed during cure. However, in-situ monitoring of void formation within laminates remains difficult to perform, and the exact mechanisms that govern void nucleation, growth and migration are not entirely understood. Process-induced deformation such as thickness variation and laminate warpage are similarly complex, as they can be caused by microstructural features, process conditions, and phenomena such as cure shrinkage, anisotropic thermal expansion/contraction, and tool-part interactions. DOI: 10.1002/pc.23773 2PDF Image | Vacuum Bag-Only Prepregs
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