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Frontal Polymerization (FP) was recently demonstrated as a faster, moreenergy-efficient way to manufacture fiber-reinforcedthermosetting-polymer-matrix composites. FP uses heat from the exothermicreaction of the solution of monomer and initiator to generate a selfpropagatingpolymerization front. In most cases, the polymerization front propagates in asteady fashion. However, under some conditions, the front experiencesinstabilities, which do affect the quality of the manufactured composite part.In this work, we use a coupled thermo-chemical model and an adaptive nonlinearfinite element solver to simulate FP-driven instabilities in dicyclopentadiene(DCPD) and in carbon-fiber DCPD-matrix composites. With the aid of 1-Dtransient simulations, we investigate how the initial temperature and thecarbon fiber volume fraction affect the amplitude and wavelength of the thermalinstabilities. We also extract the range of processing conditions for which theinstabilities are predicted to appear. The last part of this work investigatesthe effect of convective heat loss on the FP-driven instabilities in both neatresin and composite cases.

Instabilities driven by frontal polymerization in thermosetting polymers and composites