Sources of variability in uncured aerospace grade unidirectional carbon fibre epoxy preimpregnate

Two sources of variability have been investigated in uncured unidirectional carbon epoxy preimpregnate (prepreg). The variability in mass/unit area properties has been measured at various scales and compared to the specification limits as defined by the manufacturer. Both random variability and a structured variation in mass properties across the width of the roll can be detected; and as might be expected the variability rises rapidly as the scale on which the measurements are performed is reduced. The variability in fibre straightness has been studied in two ways, by direct measurements of fibre misalignments in as-delivered prepreg, and by inference from measurements of the tensile load response of uncured prepreg. A significant level of fibre misalignment is detectable in as-delivered prepreg, largely as in-plane wrinkling, although both macroscopic out of plane wrinkling and very localised small scale out of plane wrinkling can also be detected. This misalignment increases with forming, both in and out-of plane wrinkling becoming more severe. The influence of these variabilities on laminate and component response are considered.