Dataset supporting 'Manufacturing thick laminates using a layer by layer curing approach'

This dataset supports the study titled ‘Manufacturing thick laminates using a layer by layer curing approach’. The study puts forward a manufacturing strategy for the processing of thermosetting composites based on Layer by Layer (LbL) curing. The process operates additively with sublaminates placed in a heated press, partially cured while consolidating followed by loading of the next sublaminate and repeating the cycle until part completion. Coupled consolidation-cure simulation was utilised to design the process and establish its capabilities showing that halving the cure time is possible for thick parts. Mechanical testing showed that for pre-cure of placed layers below the gelation degree of cure, interlaminar properties are equivalent to those of conventionally manufactured material. A trial was carried out demonstrating successfully the LbL process. On-line measurements of temperature and compaction matched the predictions of the simulation, whilst the quality of the material produced is equivalent to that of conventionally produced composites.

The dataset comprises 9 Excel files and 4 zipped collections of microscopy images:
-File ‘913-glass_consolidation.xlsx’ reports the experimental data and modelling results for the consolidation of 913 epoxy/glass fibre prepreg. The data is organised in 3 sheets, for the different temperatures investigated. Each sheet contains the time, thickness and true strain data in 3 columns for the test results and for the corresponding model runs.
-File ‘913-glass_kinetics.xlsx’ reports the experimental data and modelling results for the cure kinetics of 913 epoxy/glass fibre prepreg. The data is organised in 7 sheets; 4 corresponding to dynamic Differential Scanning Calorimetry (DSC) tests, and 3 to isothermal tests. Each sheet contains 6 columns (time, temperature, heat flow, heat, conversion and reaction rate) of experimental results and 4 columns (time, temperature, reaction rate, conversion) of corresponding model results.
-File ‘913-glass_ILSS_partially_cured.xlsx’ contains the results of Interlaminar Shear Strength (ILSS) tests of the 913 epoxy/glass fibre composite, where the material has been assembled using a partially cured sublaminate and an uncured sublaminate. The data is organised in rows, each corresponding to a degree of pre-cure, and columns corresponding to the 5 tests caried out per case and the average and standard deviation of the results.
-File ‘913-glass_DCB_partially_cured.xlsx’ contains the results of Double Cantilever Beam (DCB) tests of 913 epoxy/glass fibre composite, where the material has been assembled using a partially cured sublaminate and an uncured sublaminate. The data is organised in 12 sheets, each reporting the DCB results for 2 specimens for each of the 6 different level of pre-cure tested, and a summary sheet collecting the results of all tests. The DCB test results for each specimen are organised in 2 columns of force versus displacement, 2 columns summarising the experimental parameters and 4 columns reporting the delamination length, displacement, force and calculated strain energy release rate. The results in the summery sheet are organised in 6 columns, each corresponding to a level of pre-cure, containing the strain energy release rates for crack lengths over 80 mm for the two specimens and the associated statistics (average and standard deviation).
-File ‘LbL_130_degC_simulation.xlsx ’ reports the results of cure and consolidation simulation of the LbL process carried out at 130°C. The file is organised in 3 sheets: one reporting the results of consolidation modelling presenting the thickness evolution as a function of time with each column corresponding to a layer of the 913 epoxy/glass fibre prepreg; and two reporting the temperature and degree of cure evolution computed by the heat transfer simulation of the process organised in columns corresponding to the position of a node (temperature) or an element centroid (degree of cure) of the simulation.
-File ‘LbL_110_degC_simulation.xlsx ’ reports the results of cure and consolidation simulation of the LbL process carried out at 110°C. The file is organised in 3 sheets: one reporting the results of consolidation modelling presenting the thickness evolution as a function of time with each column corresponding to a layer of the 913 epoxy/glass fibre prepreg; and two reporting the temperature and degree of cure evolution computed by the heat transfer simulation of the process organised in columns corresponding to the position of a node (temperature) or an element centroid (degree of cure) of the simulation.
-File ‘Monolithic_cure_optimisation.xlsx’ contains the results of an exhaustive search optimisation of the conversional processing of a 40 mm thick 913 epoxy/glass fibre composite using a two-dwell cure profile. The data are organised in 5 columns reporting the first and second dwell temperature, the first dwell duration and the resulting cure time and maximum temperature overshoot during the cure.
-File ‘Point_A_monolithic_cure.xlsx’ reports the process simulation results for one process design point on the Pareto front of the exhaustive search optimisation of the conversional processing of a 40 mm thick 913 epoxy/glass fibre composite. The results are organised in 2 sheets reporting the temperature and degree of cure as a function of time organised in columns corresponding to the locations of the nodes of the model. The results are reported for one half of the geometry due to symmetry of the solution.
-File ‘LbL_130_degC_trial.xlsx ’ reports process monitoring from an LbL trial of the 913 epoxy/glass fibre prepreg carried out at 130°C. The file is organised in 1 2 sheets reporting consolidation and temperature results. The consolidation results are organised in 6 sets of 2 columns each reporting the time and position of the top of each of the 6 sublaminates deposited during the process. The temperature results are organised in 7 columns; the 1st column reporting time and the other 6 the temperature at mid-thickness of each sublaminate.
-File ‘Optical_Conventional.zip’ contains 9 optical microscopy images (jpeg) of cross sections of 913 epoxy/glass fibre composite processed conventionally.
-File ‘Optical_LbL.zip’ contains 9 optical microscopy images (jpeg) of cross sections of 913 epoxy/glass fibre composite processed using the LbL process.
-File ‘SEM_Conventional.zip’ contains 8 scanning electron microscopy images (tiff) of cross sections of 913 epoxy/glass fibre composite processed conventionally.
-File ‘SEM_LbL.zip’ contains 8 scanning electron microscopy images (tiff) of cross sections of 913 epoxy/glass fibre composite processed using the LbL process.