Final Project Proposal: AeroQure Process Optimization and Analysis

This engineering project proposal focuses on AeroQure process optimization, particularly in the context of composite materials and aerospace applications. The proposal explores the use of pre-impregnated fibers (prepregs) and epoxy resin curing, highlighting the importance of understanding kinetic processes in thermoset curing. The document reviews the Quickstep technology, a method for manufacturing composite parts, comparing it to autoclave processing and discussing its advantages in terms of cost-effectiveness and production efficiency. The proposal outlines the potential characteristics of Resin Spray Transfer and its application in various industries, including automotive. The report emphasizes the need for detailed modeling of the curing process and the use of techniques like rheological analysis, dynamic mechanical analysis (DMA), and differential scanning calorimetry (DSC) to monitor and optimize the process. The project aims to enhance processing parameters to generate high-quality parts, reduce experimental requirements, and improve the overall efficiency of composite manufacturing.

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INTRODUCTION
The fibers which are pre-impregnated are commonly refered to as pregregs have been applied in
various fields so as to assist in the generation of parts of composite whose qualities have been
extremely high. A result of the use of the reinforced concretes has seen the applications of the curing
interests in the case of epoxy resin as a new technique or mechanisms. Chemical reactions which
accompany the processes of curing are relied upon in the determination of the resin’s morphology. This
subsequently leads to the determination of the properties or characteristics of the thermoset resins after
the processes of curing. Several research works have been carried out to assist in the analysis of the
various epoxy resin formulation in the case of relationship between the morphology of processing and
properties (Arias et al.2017).
The starting pace for the evaluation or analysis process that is usually very crucial as far as
understanding of the mechanisms is concerned is closely related to the kinetic processes. This process
of kinetic is usually part and parcel of the reaction technique used in curing. In this particular research
proposal, the viewed sources of literature work have focused on the kinetic processes and other
mechanisms used in the thermoset curing. Regardless of the significant efforts which have been
subjected to experimental work as well as evaluation by the researchers in relation to the epoxy resin
treatments, a numbers of issues still remain unresolved (Aversa et al.2016). This will include
verification of the contradicting information provided by the previous scholars in the same field s that
unnecessary confusion can be effectively eliminated and records set straight.
Several research work evaluation have foreseen an increase in the interest of modelling as far as epoxy
resin composite processing is concerned based on the concept of the design as well as rapid
manufacturing by the use of computers (Hwang et al.2018). The primary aim therefore will be
enhancement of processing parameters which are responsible for the generation of parts with very high
quality and greater consistency. This will consequently assist in the reduction of requirements of

several experiments on the cure of new components and their final establishment as speculated in
circular manner. In case a properly structured model is used, it is easier to practically monitor the
system’s behaviour ta the process of curing and even its ultimate condition. One of the important tools
for such kinds of the model will include giving a proper definition or illustrated description on the
curing kinetics in the AeroQure Process Optimizations. Although it is expected that curing kinetics’
may be complicated in one aspect or the other as a result of the complex processes involved and
shortage of chemistry knowledge of curing of epoxy resin, the process must be scientifically analyzed
for effective results to be obtained.
The various mechanisms of the experiments which have been considered t be appropriate for this
particular research work as far as monitoring of the reaction of curing process is concerned for the
thermosetting system will be cited rheological analysis, dynamic mechanical analysis which is
commonly refered to as DMA and finally differential scanning calorimetry which is commonly known
as (DSC). The determination of the required heat flow will be effectively determined by the use DSC
technique. This heat is required in the maintenance of the samples’ temperature at the optimum value
further showing detailed information on the process of curing as well as the sub-activities like
degradation units. Similarly, the DMA test will involving specimen loading while at the same time it is
being subjected to bending forces so that the produced capacities of displacement can be used in the
determination of the properties of the materials.
Background Information
Processing as illustrated in quickstep mechanisms
In the aerospace industry, reliable techniques are required in the manufacture of the aero structures. It
is for this reason the researchers have identified experimentally autoclave and sandwich schemes cure
of thermoplastics or thermosets as the best or most reliable technique. In case Sandwich Schemes are
used in the processes of curing, high temperatures and pressures will be needed, longer hours of curing

and finally heavy and supportive tooling with right equipment. It is important to note that autoclave
processing has increasingly become very undesirable due to the following reasons: Increased capital
expenditure and complexity of the properties and processes involved, required longer time for
commissioning and finally comprehensive demands on the system infrastructure.
However, in order to strike a balance the rates of production must be increased while at the same time
reducing the aerospace time scale. The requirement is not easy to achieve with the application of
conventional traditional methods of manufacturing of autoclave. This implies that development of a
technique which is cost-effective is just but unavoidable as far as processing is concerned. It will be
developed to assist in the production of aerospace parts which are capable of meeting the standard
requirements. The process should be carried out at relatively lower values of investments in terms of
capital expenditure and within the shortest time possible.
Manufacture of composites requires several techniques. One of the potentially identified techniques is
called quickstep. This particular technique has remained to be a pure idea of Quickstep Technologies
Pty Ltd in Perth which is located in the regions of Western Australia capital. As a proof of ownership,
the idea was completely patented in the year 1966. The involved principles of quickstep technique have
been illustrated comprehensively in the diagram shown below.
Figure 1: Quickstep process Diagram
About Quick Step Process

The principle of operation of Quickstep is through quick invitation of heat application in AeroQure
Process optimization. This heat is used in the lamination of composites that have been introduced
between two balanced as well as floating designed molds, Depending on the current value of
temperature; the state of molds can be in semisolid. The separation of the curing parts and molds from
HTF by unique membrane can be achieved when HTF which is a fluid of transfer of heat is made to
pass over these part components at very high velocity. By so doing, the process of autoclave will be
much slower since there will be provision of much faster cycle as for the case of the Quickstep cure.
Achievement of such kind of result will be enhanced with increased capacity of heat and fluid thermal
conductivity. It is these parameters which are responsible for faster as well as more efficient heat travel
than autoclaves of nitrogen or air-filled structures.
Figure 2: Quickstep framework (Lebaupin et al.2017).
The time frame which is recommended for the Quickstep heating as well as cooling will range from as
low as 10e12 K/min. It has been made achievable practically by the setup of Quickstep. During the process
of composite heating and subsequent cooling of the composites in process, the illustrations of reactions
which are isothermal in nature are deliberately ignored despite the fact that it is very crucial as for the case of

projected lay-up. This is due to the fact that the removal of excess heat is achieved by the use of circulating
fluid. The accumulation of this heat is regulated and its adverse consequences are prevented from
occurrence. Interesting to note is that the techniques of Quickstep are usually characterized by very low
pressure unlike for the case of the processing in autoclave.
The value of the pressure has been approximated by the researchers and scholars remains at 10 kPa. The
value is much lower compared than 700 kPa which is used externally in the case of the autoclave
processing. Considering that the external pressure usually characterize solvents which are volatile in
the case of autoclave technique, practical collapse of the same voids may be used as strategy in the
removal of voids in AeroQure Process optimization. Void removal step is very crucial step in the
processing of Quickstep technique. There are several advantages which characterizes Quickstep
technique when compared with autoclave processing. Just from the onset of the application or the
invention of the technique of Quickstep, these benefits have remained to be outstanding. This goes
alongside introduction with other individual parts of the main components that have been produced
using the same technique of manufacturing
The products are super and they can never be compared to the part component which has been
produced by the use of other techniques called autoclave. These components have displayed desirable
properties such as high strength, stable stiffness, good surface finish and perfect appearance.
Averagely, it has been estimated the grade of aerospace content is just at 2%. Another crucial
parameter which has a direct bearing on the .quality of the product is the low pressure which favors
activities of Quickstep technique. The result is a light mold which is not only safe but also beneficial
through savings on the costs. This reduces the cost of production although with the involvement of
rapid processing. The unique features allow the Quickstep to reduce rapid processing hence support of
mass production (Lebaupin et al.2017).
Quickstep Application in the Automotive Industry

As stated before, there was a premature perception that this particular technology was only beneficial
to the industry of aviation. However it later emerged that several concepts of this technology have
direct application in other industries of the automotive. To this effect, classification has been narrowed
down to the use of an autoclave as the best approach. Having been successfully applied in the industry
of aerospace, the next target or aim of the technology pioneers is to have its concepts applied in the
industry of the automotive in general (Shapiro et al.2016). One of the typical cases of aggressiveness
on the side of the implementers included manufacture of the advanced materials by a team of workers
drawn from Quickstep and Victorian Centre in the year 2007. This would later be regarded as an
extension of D and R. The main aim was a deliberate attempt to have the two industries of aerospace
and automotive merged. Interesting to note was that the merger later became the basis of Quickstep
technology in automotive which has since gained popularity.
The analysis of the technique showed that most of the particles of the metal that are present inside the
engines is because of the normal wear having the size of the particle less than 15 μm for engines
number one and three, while less than 10 μm in the aerospace component number two. The figure
below shows the samples Quickstep and Autoclave after the ferrography test. The generation of the
normal rubbing wear particle took place due to normal sliding wear within the engine and exfoliation
of shear mixed layer parts involved in the exercise of AeroQure Process optimizations. The particles of
rubbing wear consist of flat platelets, of about 5μm or less, but they always range to 15μm depending
on the application of the equipment (Gan et al. 2017).
Therefore, there must be a very little or even no surface texturing visibility as well as the thickness
which should not greater than 1μm. The result from the samples number one and number two (in which
there was no abnormal wear particles have been detected) are compared, then the confirmation was that
the unit was undergoing major to catastrophic mode of abnormal wear. The result was then based
within the combination of one of the highest wear particle concentration along with Quickstep analysis

result, therefore the sample was being rated to be a critical and the user is to be notified to ensure
immediate action.
Potential characteristics of Resin Spray Transfer
The resin sprayer transfer operations are within the basis of resin system novel composition. The
analysis of the report indicates that several companies taking place in the resin system commercial
processes such as production, manufacturing together with development has shown a very great interest
as well as devising the necessary system of RST. The RST system matrix consist of pair of vital
attributes including ‘’rapid time of cure’’ and ‘’low cost’’. The exothermic reactions occurring during
polymerization process always stimulate the thermal effect which may make part burn (Shapiro et
al.2016). The regulation of exothermic reaction is done using several retardants by commercial resin
manufacturing resulting to a very high incurred cost. A lot of heat being produces by exothermic
reactions is being regulated through a quickstep therefore, decreasing the cost of matrix system because
the process of quickstep does not necessitate exothermic retardant application of RST composition.
Figure 3: Resin Spray Transfer Cell (Shapiro et al.2016)
The RST technology is mechanized highly to ensure that the cost of labour is significantly reduced.
The high cost requirement of freezing as well as clean rooms are not required since the process does

not need the prepregs applications. The carbon fiber mechanized use and resin system also decrease a
greater value of costs. Due to surface finishing of the high quality which mold provided, some of the
requirement processes are therefore eliminated like bogging and sanding, therefore reducing the cost
spent. Direct potential spray of mold primer, reusable vacuum bags application as well as application
of less expensive molds are considered to be some of other practices which help in minimizing the cost.
Sample cases of Success and Latest Developments
The analysis conducted by Quickstep in some years past, recognized RST to have excelled the most
difficult test concerning the issues of environment since carbon fiber body panel designed one of the
most luxurious car designer within Australia. The report from Quickstep showed that it was not any
easy in acquiring the highest pain finish having carbon fiber components as well as literally maintain
like long duration standards as within the metal composites. The further report from Quickstep state
that the small figure of composite technologies as well as quality attained through benchmark may only
delivered the best standards through RST only when the cost is reduced greatly.
The aims of the project and deliverables
The project majorly aims in achieving an Aero Qure Process Optimization. Therefore, these are the
deliverables of the projects:
 The first thing to be done so as to correlate the viscosity, conversion as well as the experience
Tg in the period of the isothermal heating to be guided using rheometer aborting runs within a
specific time interval. The DSC quenched and analyzed the sample.in most cases diagrams are
being used for the illustration of the schematic process that will be followed so as to get DSC
sample during rheometer run (Joshi and Sheikh 2015).
 The second is plotting viscosity and Tg as time function of the sample heated in the rate of 9.80
degrees Celsius per minute. The expectation is that viscosity will reduce by 2 magnitude orders
as per the approximation. This is because of the higher dependency on strong temperature. The

Tg value is being expected to be constant in the initial curing stage, despite a huge reduction in
the viscosity.
 The third step is conversion as well as complex viscosity which is being plotted as curing time
function for any sample having the rate of heating of 9.80 degrees Celsius per minute. The
initial conversion expectation by the DSC is noted. Since this may partially react with the
prepreg powder in the conversion stage B.
 The last step is about the relationship between the cure degree and viscosity is being determined
using a careful combination of the rheometry use as well as other thermal analysis methods.
The project specific objectives
The epoxy 8552 prepreg is considered as one of thermoplastic toughened high performance epoxy that
is used in advanced materials manufacture used within the military. Thermosetting system cure
behavior understanding is considered to be very crucial in development and optimization of
composited in the period of fabrication processes. Rheological behavior together with cure kinetic is
being evaluated using differential scanning calorimeter which also referred as DSC, the (DMA)
rheometer and dynamic mechanical analysis.
Benefits as well as the applications of the project
The cost effective ways automobile manufacturing parts are being evaluated on a daily basis. The
studies always focused on thermoset composite uses which are very reliable. At the same time,
Quickstep processing emergency is one of the advance thermoset composite methods being treated in
the market to add the market value. The method is therefore more popular within the aerospace
industry as being practiced by Quickstep Pty Ltd may assist increasing the high volume production
requirement. The aim of the projects at achieving AeroQure process optimization within the field must
be put into consideration, therefore the production is being increased within the automobile sector.
Rationale of the project

The rheological characterization that is witnessed among the composite matrix resin is becoming very
important increasingly. The information of the gel temperature, characteristics flow and viscosity is
very useful in the new selection of the new system of resin as well as in the preliminary parameters
establishment. Although, there are some few studies that have reported in the literature majority. The
rheological epoxy prepreg evaluation deserves giving a further attention by many researches and
scholars. During rheological analysis process, there is molecular mobility measurement as the
temperature or time function (Ji et al 2019). Any difference within molecules mobility is too treated to
be a perfect reflection of viscosity changes in the cure process or a crucial stage as far as AeroQure
Process Optimizations is concerned.
The results from both DMA and DSC technique help in to provide an-depth material characterization
by thermal properties exploitation. Most severe problems that is being related to the epoxy resin
application within its system which are preimpregnated meaning that they are always very brittle
inherently. Therefore, is has been the basic subject of several studies that focuses matrices toughening
of most of the epoxy without necessarily having compromising their attributes (Yakout et al.2017).
Few of some desirable characteristics which should be preserved such as having high temperature of
glass transition (Tg), high modulus as well as advantageous ratio of strength to that of weight. Most of
rubber additives as well as thermoplastics have gotten so much attention of having achieving this
specific goals due to their ductile nature, both high Tg and modulus. These have actually proved as
very effective within the high cases of cross-linked the proxy resins systems. There is a very close
relationship between structure of network, mechanical properties and kinetic reaction; therefore it is
very important to understand epoxy cure kinetics reactions (Raponi et al..2018).
While, the rubber modifiers introduction and thermoplastics introduction has led to further
complexities notification. These types of complexities come from the interaction between
thermoplastic and rubber with the epoxy materials that are being affected by the cure process. During
this specific study, DSC, DMA and even techniques concerning rheological will be applied during the

investigation on some kinetic cure reaction parameter as for the recent 8552 epoxy system modified to
use thermoset, which is impregnated into carbon reinforcement as well as been finally evaluate curing
cycle use. Particularly the targeted curing cycle may be required in polymeric composites manufactures
which are very relevant within the fields of aerospace. Several assumptions are used in the process
(Kumar, and Nair 2017).
However, there is one assumption which is outstanding which is related to the heat evolution by the
recorder DSC. This heat evolution was found to be proportional directly to the epoxy group
consumption degree within the members of epoxy resin. What this proportionality mean is that the
group which is considered to be reactive will be of the same amount as the agent used in curing
process. The dynamic DSC therefore will serve as the primary source of the kinetic data alongside
rheological undertaking measurements. Data will also be obtained from other sources including
dynamic and isothermal DMA measurements which are very common during the curing process
reactions.
Study Justification and its Significance
Initially, the chemical study had been basically set aside for the aerospace industry and other related
firms with similar applications. This was the reason why it had been regarded as a technology of an out
of autoclave. Since its introduction into the aviation business successfully, the following crucial
objectives have been served by the innovation and potential realized. In the previous years for example,
the two known firms had corporation between them. The two forms were Quickstep and Victorian
Centre. Their cooperation was concerned with propelled materials assembly that are utilized mostly in
the case of D and R (Portolés et al 2016). Also other desirable programs of the aerospace were under
the consideration by the process. In other words, the centre was to assist in the development of other
two businesses related to aviation and car. As a result of this successful merger, there was embracing
efforts of Quickstep innovations.