Porosity investigation in carbon/epoxy composite materials

The growing demand for high-performance composite materials in the automotive and aerospace industries has led to continuous advancements in carbon/epoxy systems. One of the key challenges in composite manufacturing is controlling porosity, which can significantly impact mechanical properties such as interlaminar shear strength, modulus, and tensile strength. This study explores how vacuum bagging and autoclave processing parameters influence superficial porosity in carbon/epoxy composites, using the Taguchi design of experiments (DoE) methodology, focusing on key processing variables like tool material, curing cycle parameters (temperature, pressure, dwell time), vacuum bagging materials, and release agents. To assess superficial porosity, imaging techniques such as scanning electron microscopy (SEM) and optical microscopy were employed, with quantitative analysis performed using ImageJ2 Fiji software. This research provides valuable insights into the relationship between processing parameters and porosity, offering practical guidelines for optimizing composite manufacturing. By refining process conditions, manufacturers can enhance surface quality, reduce defects, and improve the reliability of composite components. While the study is primarily focused on superficial porosity for aesthetic considerations, the findings contribute to broader efforts in improving composite material performance, highlighting effective strategies for reducing porosity and ensuring higher-quality composite production.