In-situ pressure enhanced processing of composite articles

Abstract

A method for making a composite article comprises securing a layup over a form. The layup including a plurality of dry intermediate reinforcement plies wrapped around an inner reinforcement ply. Resin is infused into the layup under vacuum. The resin-infused layup is consolidated under pressure and cured.

1 . A method for making a composite article, the method comprising:
 securing a layup over a form, the layup including a plurality of dry intermediate reinforcement plies wrapped around an inner reinforcement ply;   infusing resin into the layup under vacuum;   consolidating the resin-infused layup under pressure; and   curing the consolidated layup.   
     
     
         2 . The method of  claim 1 , wherein the plurality of dry intermediate reinforcement plies are wrapped in tension. 
     
     
         3 . The method of  claim 1 , wherein each of the plurality of dry intermediate reinforcement plies includes a fabric composition selected from one or more of: carbon, fiberglass, silicon carbide, aramid, and glass. 
     
     
         4 . The method of  claim 1 , wherein a fabric composition of the inner reinforcement ply is the same as a fabric composition of at least one of the dry intermediate reinforcement plies. 
     
     
         5 . The method of  claim 1 , wherein the securing step includes adhesively bonding the inner reinforcement ply to the form. 
     
     
         6 . The method of  claim 1 , wherein the inner reinforcement ply comprises a pre-impregnated fabric. 
     
     
         7 . The method of  claim 1 , wherein the infusing step is performed with a longitudinal axis of the layup and the form arranged in a substantially vertical orientation. 
     
     
         8 . The method of  claim 1 , wherein at least one of the consolidation step and the curing step is performed with a longitudinal axis of the layup and the form arranged in a substantially horizontal orientation. 
     
     
         9 . The method of  claim 1 , wherein the consolidation step is performed at an applied pressure measuring between about 100 psig (about 690 kPa) and about 150 psig (about 1030 kPa). 
     
     
         10 . The method of  claim 1 , wherein the resin comprises a thermoset polymer resin. 
     
     
         11 . The method of  claim 1 , wherein the infusing step is performed at a first infusion temperature, and the consolidation step is performed at a first consolidation temperature, the first consolidation temperature greater than the first infusion temperature. 
     
     
         12 . The method of  claim 1 , wherein the composite article is a finished fan containment case having a fiber volume of at least about 60%. 
     
     
         13 . A method for making a composite article, the method comprising:
 securing an inner reinforcement ply over a form to define an inner surface of the article;   wrapping a plurality of dry intermediate reinforcement plies under tension over the inner reinforcement ply;   vacuum infusing resin into the reinforcement plies to form a resin-infused layup;   consolidating the resin-infused layup under pressure; and   curing the consolidated layup.   
     
     
         14 . The method of  claim 13 , wherein the inner reinforcement ply is adhesively bonded to the tool. 
     
     
         15 . The method of  claim 13 , wherein a fabric composition of the inner reinforcement ply is the same as a fabric composition of at least one of the plurality of dry intermediate reinforcement plies. 
     
     
         16 . The method of  claim 13 , wherein the plurality of dry reinforcement plies includes a fabric composition selected from one of: carbon, fiberglass, silicon carbide, aramid, and glass. 
     
     
         17 . The method of  claim 13 , wherein the resin comprises a thermoset polymer selected from the group consisting of: an epoxy resin, a bismaleimide resin, and a polyimide resin. 
     
     
         18 . The method of  claim 13 , wherein at least one of the consolidation step and the curing step is performed with a longitudinal axis of the resin-infused layup in a horizontal orientation. 
     
     
         19 . The method of  claim 13 , wherein the consolidation step is performed at an applied pressure measuring between about 100 psig (about 690 kPa) and about 150 psig (about 1030 kPa). 
     
     
         20 . A composite fan containment case made according to the method of  claim 13 .