Autoclave curing is a manufacturing process for high-performance parts based on carbon fiber–reinforced polymers (CFRPs) used for large aircraft parts. Today, this manufacturing process is the reference in terms of quality and, therefore, the manufactured parts’ mechanical performance and robustness. However, several parameters can impact the quality of the parts resulting from this process, which requires optimizing key manufacturing parameters. In this study, the effect of autoclave process parameters (i.e., temperature, pressure, and vacuum-pressure) on the glass transition temperature (Tg), laminate compressive modulus (LCM), laminate compressive strength (LCS), and interlaminar shear strength (ILSS) was investigated using three factors, three-level Box–Behnken design (BBD) and response surface methodology (RSM). In addition, the interactions of processing parameters with Tg, LCM, LCS, and ILSS were investigated, making this study an essential investigation for accurately selecting processing parameters. Thus, there is a functionally non-linear relationship between the interaction of the autoclave process parameters. Therefore, these parameters were optimized using RSM with the maximum Tg, LCM, LCS, and ILSS. The optimization and validation of the obtained models were carried out with an average relative error below 3% for all thermomechanical and mechanical properties, indicating that the BBD and optimization were correct. Because of this, the established regression models can accurately predict the Tg, LCM, LCS, and ILSS in autoclaved epoxy/carbon composite laminates.

Process parameters for the autoclave cure method are critical to controlling manufacturing-induced microstructure and composite laminates’ physical and mechanical properties. The effect of temperature, pressure, and vacuum on the degree of cure, density, fiber volume fraction, and void content of laminated composites was investigated by response surface methodology (RSM) and Box–Behnken Design (BBD), along with the application of analysis of variance (ANOVA), to examine the importance of regression models. The results showed that the degree of cure highly depends on the temperature. At the same time, for density, the linear effect of the pressure was the most significant term, followed by the interaction between the temperature and pressure, the quadratic terms of vacuum and pressure, and the linear terms of temperature and vacuum. All the linear terms, quadratic terms of pressure and vacuum, and interaction between temperature and pressure were significant for fiber volume fraction. However, void content has only five significant terms (the linear effect of the pressure followed by all the quadratic terms and the linear term of vacuum). The predicted responses using quadratic models were in good concordance with the experimental values ( R² values were above 98% for all responses).

The final mechanical properties of composite laminates are highly dependent on their curing cycles in the autoclave. During this cycle, the temperature, pressure, vacuum, and treatment time will influence the quality of manufactured parts. The void content is considered the most harmful defects in carbon/epoxy laminates since they weaken the matrix-dominated mechanical properties such as interlaminar shear and compressive strengths. In the present work, differential scanning calorimetry is used to characterize the influence of time/temperature on the behavior of the epoxy resin. Then, a series of [0/90/−45/+45]s laminates composites are autoclave-cured under various applied pressures to evaluate their impact on microstructure and mechanical properties. The interlaminar shear modulus, interlaminar shear strength, laminate compressive modulus, and laminate compressive strength at room and operating engine temperature were measured. The correlation between microstructure and mechanical properties was also studied. The mechanical properties of manufactured carbon/epoxy laminates are found to be dependent on pressure and microstructure. These results are explored to establish an optimal autoclave pressure route that would minimize porosity without counterbalancing mechanical properties.