Determination of void statistics and statistical representative volume elements in carbon fiber-reinforced thermoplastic prepregs

Void consolidation of high-performance thermoplastic composites strongly depends not only on average void content but also on the distributions of void size, shape, and location within the prepreg materials. High-resolution 3-D X-ray microcomputed tomography shows that voids in carbon/poly(ether ether ketone) (AS4/APC2) prepreg are rodlike with major axis along the fiber axial direction. In order to accurately characterize the void microstructure, a detailed study was conducted to quantify the statistical distribution of void content, void length, equivalent void diameter, and void aspect ratio. Resolution of 1.48 μm/pixel provided a balance of measurement accuracy and inspection time. Suitable statistical distribution functions were found to describe the void length, diameter, and aspect ratio. For each void property, a sub-statistical representative volume element (SRVE) was determined. The SRVE of the overall void microstructure is defined as the maximum dimensions of the sub-SRVEs. In case of AS4/APC2 tape, the SRVE was found to be 6.1 mm in length (fiber direction), 27 mm in width (transverse to fiber direction), and 0.18 mm of full prepreg thickness.