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Materials. Experiments were carried out using two kinds of prepregs designed for OoA processing. The first, denoted “prepreg A,” consisted of a toughened epoxy resin (Cycom 5320) and a five-harness satin (5HS) carbon fiber fabric (T650-35 3K). The second, “prepreg B,” was comprised of a later-generation OoA resin (Cycom 5320-1) and an eight-harness satin (8HS) carbon fiber fabric (T650-35 3K). Both fabrics possessed the same areal weight (375 g/m2). The two resins can, and were, cured at the same temperature. However, the resin of prepreg B was less reactive, exhibiting a longer out-life (30 days at ambient conditions, versus 21 days for prepreg A), thus requiring a longer cure at a given temperature. Note that the freezer storage time of prepreg A exceeded the 12 months freezer storage time stated by the manufacturer, resulting in reduced tack and potentially other resin degradation phenomena, whereas prepreg B underwent negligible storage time, and was therefore comparatively pristine. Both materials were used within the study because, as described below, prepreg A was more prone to voids and consequently highlighted several trends. Cure. The laminates were manufactured using traditional OoA/VBO prepreg processing protocols. Figure 1 shows details of the layup configuration. Prepreg plies measuring 76.2 mm (width) by 63.5 mm (flange) by 63.5 mm (flange) were laid up on non-perforated release film in the 0o direction (along the laminate length). Edge-breathing dams, which provided paths for air evacuation while preventing resin bleed, were placed along the laminate perimeter. A second non- perforated release film was placed on top of the laminate. Two layers of breather were applied evenly on the top of the parts within the bag. In some cases, pressure strips were used to intensify the compaction pressure locally, at the corners. The vacuum bag was finally set, with excess bag material located at the corner region to prevent bridging. After a vacuum bag was assembled and vacuum was drawn with a stand-alone vacuum pump (Busch R5), a leak test was performed by DOI: 10.1002/pc.23773 8PDF Image | Vacuum Bag-Only Prepregs
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