Characterization of melded carbon fibre/epoxy laminates

‘Melding’ is a novel in situ method for joining thermosetting composite structures, without the need of adhesives. Laminate joining is achieved using uncrosslinked resin matrix of the pre-preg. This study used Hexply914C pre-preg material to characterize melded CFRP structures produced using the melding method. A designated area of a laminate was maintained at temperatures below 40 °C retaining uncured (B-staged) material, while the remainder of the laminate was cured at 175 °C. After a 2.5 h cure cycle, the cured region showed a high degree of cure (0.88) and glass transition temperature (176 °C). The uncured area of the same laminate was cured in a second stage, simulating an in situ melded joint. By controlling the temperature and duration of the intermediate dwell and affecting minimum viscosity values prior to final cure, low values of porosity (<0.5%) were achieved. The mechanical properties of the resulting joint were consistent throughout the melded laminate. Flexural strength (1600 MPa), flexural modulus (100–105 MPa) and short beam strength (105–115 MPa) values observed where equivalent or greater than those found in the recommended autoclave cured control specimens. After the entire laminate was post cured, glass transition temperatures of 230 °C (peak tan δ) were observed in all areas of the laminate.