The Quickstep proprietary manufacturing process is a range of technologies developed and patented by Australian company Quickstep Technologies Pty Ltd, with the assistance of Commonwealth Scientific and Industrial Research Organisation, an Australian public sector R&D organization, which can be used in out-of-autoclave fabrication of composite components from advanced composite materials. The balanced pressure, heated mold process promises reduced cure cycle times and product weight, as well as increased strength and improved appearance. Products produced via Quickstep processes have superior properties to products fabricated by conventional atmospheric cure techniques and have properties generally equal to or better than high pressure autoclave techniques. Quickstep process cycle times are typically 30 minutes to 60 minutes for most resin systems, a significant time saving over the 3 hours to 8 hours required in autoclave curing processes, while achieving aerospace grade void contents of less than 2%. Significant scrap rate reduction can also be expected that is otherwise incurred from interrupted cure cycles, as well as reduced capital, tooling, and lower operating costs with energy usage 70% to 90% less than for the equivalent autoclave process. The technology allows large composite parts to be fabricated to aerospace standards together with the added flexibility to co-cure or meld components to produce more structurally integrated complex parts.

The Quickstep process uses a lightweight ‘clamshell’ like mold equipped with one or more flexible silicone bladders on each mold side that rapidly applies heat to the enclosed uncured laminate stack. The flexible bladders, which permit the laminate to be compressed without subjecting the mold to distortion or stress, have the ability to be rapidly flooded with heat transfer fluid (HTF) so that the mold surface can be heated or cooled far more quickly than is possible with liquid piped inside solid tooling. Three separate tanks are used to contain glycol HTF maintained at three temperatures from cold (room temperature) to hot (up to 400 degrees Fahrenheit). Vibrating HTF applied at constant low pressure (1 psi to 4 psi) against the tool, together with vacuum in the tooling itself, remove air as the part is compacted and cured. Three molding cells (QS1, QS5, QS20) are available that can cure surfaces of one to 20 meters square. The process can accommodate thermoset or thermoplastic prepregs, as well as wet resin/dry fiber composite systems. Though best suited to parts having moderate curvature such as airfoil-shaped components, more complex bladders can be used to mold deeper draw parts. The largest cell, which can be moved by forklift, fits into a forty foot container and can be installed in one day.

Building on its previous collaboration, Quickstep and the Victorian Centre for Advanced Materials Manufacturing have initiated a major new R&D program early this year. The program focuses on composites for aerospace applications, examining particularly how the Quickstep curing technique produces composites with apparent improvements in thermal, adhesion performance and other properties thought to result from a better cure at the micro and molecular levels. Elsewhere, the National Composites Center in collaboration with the University of Dayton Research Institute, Ashland Performance Materials, Owens Corning, Ohio State University, and WebCore Technologies Inc. will study the Quickstep process using materials enhanced with nanoparticles with the expectation of improving the performance of components produced for the aerospace and automotive industries.

Details:

Haydn James Law, Research and Development Manager

Quickstep Technologies Pty Ltd

136 Cockburn Road, North Coogee, Western Australia 6166

Phone: +61-89432-3200

Fax: +61-89432-3222

E-mail: hlaw@quickstep.com.au

URL: www.quickstep.com.au

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