The pultrusion process is one of the least expensive methods for producing structural components from advanced composite materials. The process has traditionally suffered from the inability to produce parts of repeatedly consistent quality. American Composite Tech-nology (ACT) has been actively investigating methods for increasing the consistency of pultruded composites. They feel that major quality improvements could be made if it were possible to continuously monitor the degree of cure of the composite matrix material inside the forming die as it is being cured. ACT proposes to develop a sensor compatible with the hostile environment of high temperature, pressure and abrasion inside the pultrusion die that will allow the state of the matrix material to be continuously monitored. This capability does not currently exist. Data from the sensor could be used by a smart control system to maintain product quality. The approach will be to combine commercially available sensor electronics developed by Micromet Instruments for monitoring composite cure in less hostile en-vironments with a castable ceramic substrate. During the program ACT will develop methods for transferring the conductive elements of the sensor to the surface of a mold, establish techniques for casting a protective ceramic backing, and test prototypes under controlled conditions. Commercial Applications: The sensor developed during the proposed program will enable the quality of pultruded composite parts to be continuously monitored during production. Pultrusion is the lowest cost composite production method, and is rapidly growing in importance. A sensor capable of monitoring degree of cure will receive widespread application.
