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Figure 5: Defects in corner laminates: (a) concave corner, (b) convex corner of the fiber bed were consistent through the thickness. In the convex corner, no resin accumulation was observed, although the radius of curvature of the fiber on the mold side was significantly less than others on the bag side, leading to convex corner thinning and increased thickness variation. To identify the fundamental causes of thickness non-uniformity, microscopic inspection was used to measure the CoV of the fiber bed thickness, independent of the overall laminate thickness. Figure 5 (a) shows how the measurement of both thickness values was performed at a given location. Figure 6 compares the overall thickness variation measured from such micrographs to that of the fiber bed thickness in prepreg B laminates. Figures 6 (a) and (b) display graphs of four- ply and eight-ply data, respectively. In concave corner laminates, the CoV of the fiber bed was significantly less than that of the laminate thickness, but remained greater than that of the flanges. This difference, along with observations of consistent fiber curvature radius through the thickness, suggested that thickness variation in concave laminates was caused mainly by resin accumulation at the concave corner. The stiffness of the fiber bed and its inability to conform to the sharp mold radius during low pressure processing was a contributing but minor cause. Conversely, in convex DOI: 10.1002/pc.23773 14PDF Image | Vacuum Bag-Only Prepregs
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