Limited pressure expansion tooling

A method of limiting the pressure applied to a lay-up of a composite article by a thermally expansive material during consolidation thereof in a curing device, said lay-up having a minimum allowable pressure necessary to consolidate the lay-up and a maximum allowable pressure at which the lay-up can be consolidated without said material intruding into said lay-up, said method comprising:

• providing a limited pressure expansion material including a volume of said thermally expansive material, said volume substantially free of gas bubbles and having a plurality of hollow microspheres uniformly dispersed throughout said volume, each of said microspheres subject to implosion at a pressure no less than said minimum allowable pressure and no greater than said maximum allowable pressure;
• packing said limited pressure expansion material about said lay-up within a cavity of said curing device so as to substantially eliminate any voids from between the limited pressure expansion material and the lay-up and from within the cavity;
• and,
• sealing the lay-up and the limited pressure expansion material inside said cavity and heating said limited pressure expansion material to a temperature at which the pressure exerted by the limited pressure expansion material within said cavity exceeds said minimum allowable pressure.