Thermomechanical Behaviour of Chemically Cured Polymer Composites: Preliminary Analysis of the Scale Effect

This study examines the influence of scale effects on the thermomechanical and structural performance of chemically cured, glass-fibre-reinforced polyester composites. Two reinforcement architectures-plain 0/90° fabric and biaxial fabric-were analysed to assess differences in resin flow, curing behaviour, and mechanical characteristics. Differential Scanning Calorimetry (DSC) was employed to characterise cross-linking kinetics at 15 °C, 19 °C, and 25 °C, demonstrating that higher cure temperatures markedly accelerate gelation and cross-linking. Composite plates were manufactured by Light Resin Transfer Moulding (L-RTM), and static tensile tests were conducted in accordance with PN-EN ISO 527-4. The results confirm that reinforcement architecture strongly affects processability and mechanical performance. The 0/90° fabric provided superior resin permeability and shorter infusion times, whereas the biaxial fabric required higher injection pressure and exhibited longer curing duration. Statistical analysis based on Weibull's brittle strength theory verified the presence of scale effects: larger specimens displayed lower nominal strength due to a higher probability of internal flaws. Multiple regression modelling further revealed relationships between geometric and mechanical parameters: maximum (destructive) stress, Rm, was the dominant factor influencing both specimen thickness and number of layers, while deformation at maximum stress (εm) primarily determined specimen length. These findings highlight the necessity of accounting for size-dependent behaviour when designing and testing polymer composites. Considering scale effects enables more reliable extrapolation from laboratory-scale tests to full-scale components, thereby improving predictability and structural reliability in engineering applications.