Performance Evaluation and Multiphysics Process Modeling of Carbon Fiber Reinforced Thermoset Composites Using Microwave and Autoclave

In this study, IM7/Cycom 5320‐1 unidirectional prepreg has been utilized to manufacture 16‐layer laminated composites: a symmetric cross‐ply ([0°/90°] 4s ) and a quasi‐isotropic ([45°/90°/−45°/0°] 2s ) configuration. Microwave and autoclave curing processes have been employed to manufacture the laminated composites. The manufactured composite cure was assessed using differential scanning calorimetry (DSC). The quality and porosity of the microwave‐cured parts were juxtaposed to those of autoclave‐cured parts through optical microscopy and micro‐computed tomography (micro‐CT) scanning. Mechanical characterization of the microwave‐cured panels was conducted using uniaxial tensile and flexural tests, with results juxtaposed to autoclave‐cured samples. Experimental characterization revealed that the microwave‐cured parts exhibited nearly identical void content and mechanical performance as the autoclave‐cured parts. A multiphysics modeling approach using COMSOL was developed to foresee the manufactured composites degree of cure and temperature distribution. The numerical results were validated against DSC analysis for the degree of cure, and the temperature profile was compared to the manufacturer‐endorsed cure cycle. This multiphysics model was subsequently used for a parametric study to predict temperature distribution at 90%, 95%, 105%, and 110% of the actual microwave input power. Additionally, the model simulated temperature distribution at various laminate thicknesses (5, 3.75, 2.5, and 1.25 mm).