In a groundbreaking study published in the journal *Materials & Design* (translated as *Materials & Design*), researchers have unveiled a promising alternative to traditional resin infusion techniques for manufacturing thick and complex composite parts, with significant implications for the energy sector. The study, led by Omid Sam-Daliri from the School of Engineering at the University of Galway, Ireland, explores the use of epoxy powder in composite laminate fabrication and its potential to revolutionize industries such as aerospace, automotive, and marine.
Sam-Daliri and his team focused on the feasibility of using epoxy powder for joining unidirectional glass fibre-epoxy composite parts through a process known as co-curing. This method involves bonding composite parts during the curing process, as opposed to using adhesive joints, which are applied after the parts have been cured. The researchers assessed the effectiveness of co-curing techniques for both thin and thick composite laminates and compared the results with those of adhesive joints.
The findings were striking. Co-curing joints demonstrated a 49% higher shear strength than optimized adhesive joints, indicating a robust and reliable bonding method. To further validate these results, the team manufactured a demonstrator beam incorporating both co-curing and adhesive bonding joints, designed in the shape of a bowfoil. This beam underwent four-point bend tests to evaluate its flexural strength and damage propagation area. The results showed that both bonding types withstood the ultimate loads, with the composite part failing rather than the joints.
“This study highlights the potential of co-curing as a viable alternative to traditional adhesive bonding methods,” said Sam-Daliri. “The enhanced shear strength and durability of co-cured joints could lead to more efficient and cost-effective manufacturing processes in various industries.”
The research also included the development of a finite element model to simulate the behavior of the composite joints. The model’s accuracy was verified against the test results, with an average difference of only 8.9% in ultimate fibre direction strain. This level of precision underscores the reliability of the co-curing technique and its potential for widespread adoption.
The implications of this research are far-reaching, particularly for the energy sector. The use of epoxy powder and co-curing techniques could lead to the development of stronger, more durable composite parts for wind turbines, offshore structures, and other energy-related applications. This could result in reduced maintenance costs, improved performance, and increased longevity of critical components.
As the energy sector continues to evolve, the demand for innovative materials and manufacturing techniques will only grow. The findings of this study provide a compelling case for the adoption of co-curing techniques in the production of composite parts, offering a glimpse into the future of materials science and engineering.
In the words of Sam-Daliri, “The co-curing process not only enhances the mechanical properties of composite joints but also opens up new possibilities for designing and manufacturing complex structures. This could be a game-changer for industries looking to optimize their production processes and improve the performance of their products.”
With the publication of this research in *Materials & Design*, the stage is set for further exploration and development of co-curing techniques, paving the way for a new era of innovation in the energy sector and beyond.