Energy‐Efficient Electrical Curing of CFRP Composites: Parametric Effects and Comparative Performance of Direct Versus Pulsed Current

ABSTRACT Electrical current curing demonstrates superior energy efficiency and time‐effectiveness compared to traditional curing methods using autoclaves or curing ovens. However, achieving process stability remains challenging due to uncontrolled resistance fluctuations and methodological variations that significantly affect curing temperature uniformity. This study investigates curing mechanisms and structural properties of carbon fiber reinforced polymer (CFRP) composites under both direct current (DC) and pulsed current (PC) regimes. Critical process parameters, including copper foil‐CFRP contact area, contact resistance, pressure uniform plate application, CFRP dimensions, and electrode layering quantity, were systematically evaluated. Temperature distribution homogeneity was subsequently analyzed across varying process conditions. Comparative assessment of DC and PC cured CFRP was performed through thermal response analysis, porosity measurement, and mechanical characterization like bending and compression properties. Results demonstrated that pulsed current curing facilitates enhanced temperature uniformity and stability, reducing porosity by 36.67%. The bending strength and modulus increased by 0.675% and 3.22%, respectively, with pulsed current curing, while compression strength and modulus decreased by 7.06% and 15.83%, respectively. It is also found that the resin failure particle size was larger in the PC group, while the DC group exhibited smaller failure dimensions with more brittle fracture characteristics.