Optimizing the hot isostatic pressing process based on simulation and experimental validation of hollow structure carbon fiber/polymer composites

Abstract In order to leverage the advantages of the hot isostatic pressing (HIP) process and efficiently and stably manufacture carbon fiber reinforced polymer (CFRP) hollow load‐bearing structures, an evaluation and optimization of three processes were carried out. Based on material testing, mathematical models for the curing and rheological behaviors of the prepreg were developed, and simulation calculations were conducted using the established material model. Finally, CFRP composites were manufactured using the HIP process based on the process from the simulation calculations. The results show that process 3 is the best choice among the three forming processes, with a compaction displacement of 0.374 mm and a fiber content of 71 vol%, demonstrating better compaction performance. Samples prepared according to process 3 exhibit a high degree of consistency with the simulation results. The wall compaction displacement is 0.29 mm, with slight differences in the edge compaction conditions. The overall fiber content reaches 62–65 vol%, and the internal morphology and defects are characterized, confirming a good compaction effect. Highlights New mathematical models for resin curing and flowing were developed. Mathematical models were used to simulate and optimize the HIP process. CFRP specimens were manufactured to validate the superiority of the process.