Meaning
Structural defect emerges when trapped gases or moisture expand within a thermoplastic composite during heating cycles. This physical defect, deconsolidation void growth, reduces the interlaminar shear strength of the cured laminate. Restricting this expansion is necessary to maintain the structural integrity of aerospace components during high-temperature processing.
Material Change
Heating thermoplastic matrices past their glass transition temperature lowers the viscosity of the polymer. This material change of deconsolidation void growth occurs when internal pressures overcome the consolidation pressure of the mold. The resulting gaps between fiber layers weaken the structural frame.
Production Defect
Manufacturing lines utilize continuous compression molding to minimize internal defects. The production defect of deconsolidation void growth represents a primary failure mode during rapid heating cycles. Quality control teams reject panels that show high void content during ultrasonic inspections.
Warranty Liability
Structural failures due to internal voids can lead to expensive product recalls for composite part manufacturers. The warranty liability of deconsolidation void growth is allocated to the material processor if process parameters were not maintained. Contracts specify the allowable void percentage in delivered parts.
To avoid these costs, processors must provide detailed telemetry logs demonstrating that consolidation pressures were maintained throughout the curing cycle.
