E-BEAM CURE PROCESS FOR COMPOSITES

Electron Beam (E-beam) curing is a non-thermal, non-autoclave curing process that produces high performance composite aerospace parts.  It makes it possible to build composite structures without the need for slow, high-temperature, high-pressure curing cycles with associated expensive fabrication tools.

Materials:   E-beam compatible materials are commercially available, similar to conventional epoxy materials in their form and appearance.  For hand lay-up parts these consist of preimpregnated fabrics or unidirectional tapes with traditional reinforcements such as fiberglass and graphite fibers.  The resin systems are epoxy based but with a proprietary formulation that include cationic initiators that are sensitive to E-beam processing.  Foam and honeycomb cores can be incorporated.  Acsion Industries has also developed a compatible fast cure E-beam potting compound for introducing hard points within honeycomb panels.

Tooling:  Approaches are significantly different compared to conventional processes.  Tooling does not have to tolerate the typically high temperatures and pressures of an autoclave.  Concepts including low-cost fiberglass/polyester, wood and low-density foam.

Lay Up Process:  Composite aerospace parts and repairs produced from preimpregnated materials use similar techniques to conventional thermal processes.  The plies are laid down and compacted under vacuum and some application of heat to consolidate the uncured laminate and remove entrapped air.  The parts are prepared for cure with a vacuum bag system that incorporates an opaque covering to prevent premature cure from UV light sources.

E-Beam Cure Process:  This process uses a beam of high-energy electrons from a device called an accelerator to initiate resin cure in place of the usual autoclave that applies heat and pressure.  E-beam curing is suitable for composite parts as thick as 5 cm.  Parts are cured by spraying these electrons onto the composite part.  The cure is controlled through the application rate of the electrons and the total number of electrons or dose applied to the part.  The process is fast and easy to control.  Best of all, it is conducted at room temperature so that normal thermal stresses associated with heat curing are minimized.

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