Patent ID: 7857925

Claim:
A protocol for determining process parameters for composite patch preparation using double vacuum debulk (DVD) comprising the steps of: obtaining cure and current consolidation information of a composite material system as a preliminary baseline; determining if a rheology study is required; if so, conducting the rheology to determine resin viscosity profile upon heat up to cure temperature; evaluating the viscosity profile for initial trials; conducting initial trials on a plurality of panels with multiple variations of time/temp DVD profiles based on viscosity profile to confirm data values; evaluating trial results on at least one panel with a non-destructive inspection using 5 MHz through transmission ultrasonics; assessing panel bleed during both debulk and cure; assessing general quality appearance; measuring panel average thickness to confirm patch quality; preparing a matrix for varying time/temp profiles to pursue better results or find process limits; running the matrix variations of time/temp DVD profiles to confirm data values; assessing panel bleed for matrix variations during both debulk and cure assessing matrix panels for general quality appearance; measuring matrix panel average thickness to confirm patch quality; evaluating matrix panels with an NDI panel using 5 MHz through transmission ultrasonics; determining an optimum consolidation and defining process points at which quality drops off; and, applying protocol results to patch preparation for the material tested.