Thermal control system for thick composite laminates based on forecasting

A forecast‐based thermal control system was developed to cure thick composite laminates that produced large exothermic reactions. The system used process simulation models for heat transfer and compaction to predict future cure conditions at a designated forecast time so that the system can respond to avoid approaching adverse conditions. The thermal control system derived cure cycles that eliminated exotherms and maintained uniform through‐the‐thickness temperature gradient for 3‐cm thick AS4/35016 laminates. The on‐line results indicated that cure cycles were slightly different from off‐line simulation results, mainly because of the slow response of the hot press. Nevertheless the system was able to satisfy the cure criteria under such unforeseen circumstances, which demonstrated the flexibility of the forecasting method.