SEP 2018


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SEPTEMBER 2018 66 CompositesWorld INSIDE MANUFACTURING 1 After the hull mold is waxed and sprayed with Partall film #10 PVA mold release (Rexco, Conyers, GA, US) and Awlgrip high-build primer from AkzoNobel (Houston, TX, US), shown in photo, a layer of 150-g/m 2 0°/90° satin-weave E-glass is laid into the mold as a contact laminate (for contact, low-pressure molding). 4 The core is set in place over the cured first skin and vacuum bagged. The core set consists of perforated plain sheets of 0.375-inch/9.5-mm, 80-kg crosslinked PVC (shown in photo). It is vacuum bagged with a thin mix of microballoons (West System 407 low-density filler) and Gougeon 105/205 resin/hardener, both supplied by Gougeon Bros. (Bay City, MI, US). 5 After the core set is cured and detailed, the inside carbon skin is wet out and laid in, as shown. A bleeder layer is added and the part is, again, vacuum bagged and cured. 2 When the contact laminate is green, two plies of 200g 0°/90° carbon woven reinforcements (CWR) are wet-out and debulked between plies of plastic on a laminating table (shown in photo). They are then placed in the mold to build the first (outside) carbon skin. Additional strips and patches of 200 g/ m 2 and 300 g/m 2 0°/90° and ±45° CWR and carbon unidirectional reinforce- ments (CUR) are added to strengthen points of high stress in the center and at the bow and stern. 6 After cure, carbon-skinned foam frames and bulkhead are taped into the hull. 3 Peel ply (release fabric), P3 perforated plastic (release film) and bleeder cloth (to absorb excess resin) are laid over the carbon fiber skin and the part is vacuum bagged (as shown in photo), tented, and then heated to 90°F/32°C to encourage resin flow during overnight cure.

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