Microwave processing of advanced composites with high electromagnetic power heating

The newly developed HEPHAISTOS-technology (High Electromagnetic Power Heating Automated Injected STructures Oven System) is an internationally patented system and characterized by a very high field homogeneity (Figure 1). The system technology has been developed at Forschungszentrum Karlsruhe (FZK), Institute for Pulsed Power and Microwave Technology (IHM). Together with the partners Votsch, EADS and IFB, the microwave technology has been developed successfully to a high industrial standard. The high field homogeneity allows for the manufacture of high-quality CFRP (carbon fibre reinforced plastics) aircraft structures, for instance. Conventional tooling systems (e.g. metal tools) and qualified resin systems can be kept. It has been shown that the technology offers a high potential for saving energy, reducing processing time and even improving the mechanical performance. The advantages of this system are also investigated to be used in other industrial applications like automotive industry and wind energy. A research project funded by the German Research Ministry has been started to further improve the materials, the processes and the microwave system and to prove the applicability in various industry areas.