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This paper outlines the conversion of a domestic microwave oven for use in composite curing applications. It compares several strategies for temperature control. The converted oven has vacuum ports, connectors, and fiber optic thermocouple sensors. Experimental data are provided for each control strategy based on a 200 mm × 200 mm eight-ply prepreg laminate. The degree of cure is established for the test samples by thermal analysis techniques. Multiphysics simulation is used to model the electromagnetic and heating effects in the system, and a common and inexpensive method of approximating the available microwave power is used. The low cost of the microwave components and the ease of conversion are desirable characteristics in this application.

Although metals are the most commonly used tooling materials to cure composites, they do not provide optimal results in a microwave environment. Following a selection process based on the properties of the materials, an alternative tooling material in carbon fibre reinforced plastic (CFRP) was successfully utilised to cure CFRP panels in laboratory and industrial microwaves. The conductive carbon fibres in the tool facilitated the fast heat transfer across the part. Other tooling materials including a glass fibre cyanate ester prepreg and tooling board were trialled, although the latter exhibited damage during cure. These advantages demonstrate that the CFRP tool is a compatible material that can be used when microwave curing composites.

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The role of processing conditions and intercalant chemistry in montmorillonite clays on the dispersion, morphology and mechanical properties of two epoxy/clay nanocomposite systems was investigated in this paper. This work highlights the importance of employing complementary techniques (X-ray diffraction, small angle X-ray scattering, optical microscopy and transmission electron microscopy) to correlate nanomorphology to macroscale properties. Materials were prepared using an out of autoclave manufacturing process equipped to generate rapid heating rates and mechanical vibration. The results suggested that the quaternary ammonium surfactant on C30B clay reacted with the epoxy during cure, while the primary ammonium surfactant (I.30E) catalysed the polymerisation reaction. These effects led to important differences in nanocomposite clay morphologies. The use of mechanical vibration at 4 Hz prior to matrix gelation was found to facilitate clay dispersion and to reduce the area fraction of I.30E clay agglomerates in addition to increasing flexural strength by over 40%.

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When cured in a microwave, flat thin composite panels can experience even heat distribution throughout the laminate. However, as load and geometric complexity increase, the electromagnetic field and resulting heat distribution is altered, making it difficult to cure the composite homogeneously. Materials that absorb and/or reflect incident electromagnetic radiation have the potential to influence how the field behaves, and therefore to tailor and improve the uniformity of heat distribution. In this study, an absorber was applied to a composite with non-uniform geometry to increase heating in the location which had previously been the coldest position, transforming it into the hottest. Although this result overshot the desired outcome of temperature uniformity, it shows the potential of absorbing materials to radically change the temperature distribution, demonstrating that with better regulation of the absorbing effect, a uniform temperature distribution is possible even in non-uniform composite geometries.