152 X-ray Cured Carbon-Fiber Composites for Vehicle Use
Richard Galloway; Marshall Cleland - IBA Industrial, Edgewood, New York, USA: Anthony J. Berejka, Ionicorp+, Huntington, New York: Dan Dispenza, Nordan Composite Technologies, Patchogue, New York: Mark Driscoll, State University of New York, College of Environmental Science and Forestry (SUNY-ESF), Syracuse, New York: Daniel Montoney, Strathmore Products, Inc., Syracuse, New York,USA
E-Mail: Rick.Galloway@iba-group.com
Abstract
Carbon fiber reinforced composites were cured in molds using X-rays derived from a high current electron beam. X-rays could penetrate the mold walls as well as the fiber reinforcements and polymerize a matrix system. Matrix materials made from modified epoxy-acrylates were tailored to suitably low viscosity so that fiber wetting and adhesion could be attained. Techniques similar to vacuum assisted resin transfer molding (VARTM) and conventional vacuum bagging of wet lay-ups were used. Inexpensive reinforced polyester molds were used to fabricate vehicle fenders. Moderately low dose X-ray exposure was sufficient to attain functional properties, such as resistance to heat distortion at temperatures as high as 180°C. The matrix system contained an impact additive which imparted toughness to the cured articles. "Class A" high gloss surfaces were achieved. Thermo-analytical techniques were used on small sized samples of X-ray cured matrix materials to facilitate selection of a system for use in making prototypes of vehicle components. X-rays penetrated metal pieces placed within layers of carbon fiber twill were cured and bonded into structure so that it could be mechanically attached without concern over fracturing the composite. X-ray curing is a low temperature process that eliminates residual internal stresses imparted by thermo-chemical curing.