Effects of the addition of a cover mold on resin flow and the quality of the finished product in vacuum‐assisted resin transfer molding

For vacuum‐assisted resin transfer molding (VARTM), we propose adding a cover mold, inserted between the distribution medium and the peel ply, to achieve a higher fiber volume fraction in the final product. As the conventional VARTM process does not use a cover mold, improved processes using different rigid covers were explored. A three‐dimensional digital image correlation system was developed to monitor the thickness evolution of the vacuum package during the infusion stage. This system was validated as a full‐field displacement test. The results demonstrate that there are three advantages to using a cover mold. First, in the filling stage, a rigid cover mold can prevent shrinkage of the part at the resin flow front, and even cause slight expansion of the unsaturated part. This improves the resin flow and shortens the time required for complete infusion. Second, a cover mold can limit the amount of excess resin needed to infuse the saturated part. Third, in the postfilling stage, the cover mold can be used to accelerate extrusion of the excess resin in the package. The overall effect is to increase the fiber volume fraction in the final product. POLYM. COMPOS., 37:1435–1442, 2016. © 2014 Society of Plastics Engineers     

Flow front measurements and model validation in the vacuum assisted resin transfer molding process

Through‐thickness measurements were recorded to experimentally investigate the through thickness flow and to validate a closed form solution of the resin flow during the vacuum assisted resin transfer molding process (VARFM). During the VART'M process, a highly permeable distribution medium is incorporated into the preform as a surface layer and resin is inftised Into the mold, under vacuum. During Infusion, the resin flaws preferentially across the surface and simultaneously through the thickness of the preform, giving rise to a three dimensional‐flow front. The time to fill the mold and the shape of the flow front, which plays a key role in dry spot formation, are critical for the optimal manufacture of large composite parts. An analytical model predicts the flow times and flow front shapes as a function of the properties of the preform, distribution media and resin. It was found that the flow front profile reaches a parabolic steady state shape and the length of the region saturated by resin is proportional to the square root of the time elapsed. Experimental measurements of the flow front in the process were carried out using embedded sensors to detect the flow of resin through the thickness of the preform layer and the progression of flow along the length of the part. The time to fill the part, the length of flow front and its shapes show good agreement between experiments and the analytical model. The experimental study demonstrates the need for control and optimization of resin injection during the manufacture of large parts by VARTM.     

Experimental analysis and simulation of flow through multi-layer fiber reinforcements in liquid composite molding

Liquid composite molding (LCM) is a process in which a reactive fluid is injected into a closed mold cavity with preplaced reinforcement. Combined layers of different permeabilities are often used in LCM, which creates through thickness and inplane porosity and permeability variations. These inhomogeneities may influence the flow front profile in the thickness direction. To investigate the effect of the through thickness inhomogeneities, mold filling experiments were performed using preforms containing layers of two different fiber architectures. Aqueous corn syrup solutions were injected into a tempered glass mold containing the reinforcement stack. The progress of the flow front at various locations within the reinforcement was measured by an electrical conductivity technique based on the insertion of small wires between the reinforcement layers. Experimental data reveal the details of the flow front shape as the fluid penetrates the preform. Using these data, a model is proposed to calculate the overall in-plane permeability of the preform. Numerical simulations of the flow front progression performed with the computer software RTMFLOT developed in our laboratory are compared to the experimental flow front for various stacking arrangements. Results show good agreement between simulations and experiments and demonstrate the capability of the software to simulate multi-layer flow process.     

Numerical simulation of resin infusion and reinforcement consolidation under flexible cover

This paper presents the physical phenomena and equations governing resin infusion under a flexible cover. This composite manufacturing process known as vacuum assisted resin infusion (VARI) is analyzed here when the reinforcement is covered by a thin plastic film and resin is injected by gravity after a partial level of vacuum has been achieved in the cavity. In this process, the plastic cover is deformed as the resin fills up the mold cavity. Coupling between the mechanical deformation of the flexible cover and the resin flow inside the mold cavity is described by a set of mathematical equations with boundary conditions. Based on this model, a general methodology is developed to simulate numerically the resin flow during the infusion process. Validation of the numerical results is performed by comparison with a series of experiments. POLYM. COMPOS. 26:417–427, 2005. © 2005 Society of Plastics Engineers     

Simulations and measurements of in‐mold melt flow during the injection molding of polystyrene

Simulations are often used to model polymer flow during injection molding to design molds and select processing parameters. It is difficult to determine the accuracy of these simulations due to a lack of experimentally measured in‐mold velocimetry and melt‐front progression data. This article compares the results from commercial mold‐filling simulation software to experimental data obtained via particle image velocimetry (PIV) in a special optical‐access mold with a rectangular cavity. Moldflow was used to simulate the mold filling by a polystyrene melt in the experimental configuration, and these simulated results are compared to the appropriately averaged time‐varying velocity field measurements. Simulated results for melt‐front progression are also compared with experimentally observed flow fronts. The ratio of the experimentally measured average velocity magnitudes to the simulation magnitudes was found on average to be 0.99 with a standard deviation of 0.25, and the difference in velocity orientations was found to be 0.9° with a standard deviation of 3.2°. The corner area opposite the gate was most problematic for the simulation. The region behind the front also had a relatively high simulation error, though not as severe as that in the corner. POLYM. ENG. SCI. 2013. © 2012 Society of Plastics Engineers     

Sensitivity analysis on resin transfer molding processes with edge effect and curing reaction characteristics

The mold filling time and resin flow front shape are of fundamental importance during resin transfer molding (RTM) processes, because the former influences productivity and the latter affects composites quality. In this article, considering both edge effect and curing reaction characteristics of the resin flow process, the sensitivity analysis method is introduced to investigate the sensitive degree of mold filling time and resin flow front shape to the key material and processing parameters. The function employed to describe the resin flow front shape is defined, and the mathematical relationships of the key physical parameters, such as fluid pressure sensitivity, flow velocity sensitivity, mold filling time sensitivity, and resin flow front shape sensitivity, are established simultaneously. In addition, then the resin infiltration process is simulated by means of a semi‐implicit iterative calculation method and the finite volume method. The simulated results are in agreement with the analytical ones. The results show that under constant injection velocity conditions, both the change in the resin temperature and the alteration of the inlet velocity hardly affect the resin flow front shape, whereas the influence of edge permeability on the resin flow front shape is the greatest. This study is helpful for designing and optimizing RTM processes. POLYM. COMPOS., 36:2008–2016, 2015. © 2014 Society of Plastics Engineer     

软模/真空灌注成型带复杂孔圆盘的工艺探讨

为解决复杂复合材料构件的整体一次成型问题,提高复合材料制品的整体性能,降低生产成本,本文采用硅橡胶制备软模,利用其柔韧性解决常规模具无法一次成型的问题。并通过软模/真空灌注工艺制备了带复杂孔圆盘,以验证其工艺可行性。通过比较与其他工艺制备的复合材料性能,探讨其使用前景。结果表明,采用软模/真空灌注工艺可一次整体成型带复杂孔圆盘等复杂构件,制品性能稳定。     

Analysis of the vacuum infusion molding process

The vacuum infusion molding process is becoming increasingly popular for the production of large composite parts. A comprehensive model of the process has not been proposed yet, making its optimization difficult. The flexible nature of the vacuum bag coupled to the varying pressure inside the mold cavity results in a variation of the cavity thickness during the impregnation. A complete simulation model must incorporate this phenomenon. In this paper, a complete analysis of the vacuum infusion molding process is presented. The analysis is not restricted to the theoretical aspects but also reviews the effect of the main processing parameters. The parameters investigated in this paper are thought to be those of most interest for the process, i.e. the compaction of the reinforcement, the permeability, the infusion strategy and the presence of flow enhancement layers. Following the characterization experiments, a 1‐D model for the vacuum infusion molding process is presented. This model is derived assuming that an elastic equlibrium holds in the mold cavity during mold filling. Even though good agreement was found between simulation results and experiments, it is concluded that additional work is needed on the numerical model to integrate interesting findings from the experimental part.     

软模/真空灌注成型内翻法兰半球的工艺探讨

为解决复杂复合材料构件的整体一次成型问题,提高复合材料制品的整体性能,降低生产成本,本文采用硅橡胶制备软模,利用其柔韧性解决常规模具无法一次成型的问题。并通过软模/真空灌注工艺制备了带内翻法兰半球,以验证其工艺可行性。通过比较与其他工艺制备的复合材料的性能,探讨其使用前景。结果表明:采用软模/真空灌注工艺可一次整体成型内翻法兰半球等复杂构件,制品的性能稳定。     

Influence of alcohol pre‐infusion on the quality of VARTM composites

In the vacuum assisted resin transfer molding (VARTM) process, part‐to‐part variations such as the uncertainty in the permeability and race tracking phenomenon make it difficult to achieve consistent mold filling and ensure part quality of composites. Alcohol pre‐infusion was presented in this study as a novel real‐time monitoring and control approach for the flow process in the VARTM process, alcohol test fluid is infused before the actual resin infusion to locate the potential dry spots without using the large quantity of sensors. Then corresponding process control strategy is designed, such as opening the auxiliary gate at specific moment on those predicted dry spot locations to compensate flow defects. Moreover, alcohol can be easily removed by heat without changing the local permeability. The influence of alcohol pre‐infusion on the quality of VARTM composites were investigated in this study. The mechanical tests were conducted to verify that the alcohol pre‐infusion approach has no significant effect on composite properties because alcohol can be removed from fiber by heat and air flow. Specifically, DMA, TGA, and FTIR spectrum proved that negligible difference existed on the resin–fiber interface between the composites with or without alcohol pre‐infusion. Finally, the microscopy results revealed a similar failure path in a resin matrix. TMA results also demonstrated similar dimension stability. This alcohol pre‐infusion approach was effective when compared with computer simulation and could eliminate the occurrence of dry spots and voids without using sensors or data‐acquisition system. The control schemes were shown in a case study to be capable of compensating the flow defects and achieving desired fill patterns in the face of permeability uncertainty. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers     

Effect of nanoclay particles on mold‐filling performance in composites made via resin infusion process

This study investigates the effect of 3 and 5 wt% nanoclay (Cloisite 30B) addition on mold filling time and performance of continuous glass filament mat reinforced unsaturated polyester (UP) resin composites made by vacuum infusion process. X‐ray diffraction and transmission electron microscopy analysis as well as viscosity change in liquid state resin confirmed intercalation and exfoliation of the nanoclay in the resin system. The result shows mold filling time increase of 3 and 2.4 times for the samples containing 3 and 5 wt% nanoclay, respectively, compared with nanoclay‐free sample. This increase in mold filling time is directly attributed to the increase in resin viscosity. Filtration of nanoclay particles were observed in the resin flow direction. Result showed 8 and 14% filtration of nanoclay in flow direction for the samples with 3 and 5 wt% nanoclay content, respectively. Nanoclay containing specimens prepared from near resin entry port area showed relatively higher flexural and tensile modulus and as well as strength compared to specimens prepared from area close to vacuum port area. The result showed best performance for 3 wt% nanoclay containing specimen. However, impact strength decreased about 6.1 and 10.8% for 3 and 5% nanoclay, respectively. POLYM. COMPOS., 2012. © 2012 Society of Plastics Engineers     

Key factors affecting permeability measurement in the vacuum infusion molding process

The composites industry, under increased environmental constraints, is seeking to shift from existing open mold manufacturing processes for composite parts. A promising manufacturing technology known as the vacuum infusion molding process is gaining acceptance among composite-parts manufacturers since it involves low tooling cost and allows complete elimination of volatile organic compounds (VOC). The process is similar to the resin transfer molding process; however, in the vacuum infusion technique, a polymeric film, often referred to as vacuum bag, replaces the stiff mold cover. The film is sealed against the lower half of the mold, at the periphery. Air expelled from the mold cavity results in the compaction of the reinforcement by the atmospheric pressure present on the outer side of the polymeric film. Finally, resin impregnates the mold cavity, usually through a resin distribution channel. The process is mainly developed for large-scale structures, where material cost is an important parameter and users cannot afford any production pitfalls. Among process parameters that affect resin flow in the vacuum infusion molding process is the permeability of the reinforcement stack, which has to be measured and evaluated taking into consideration the requirements of the process. A possible approach is the definition of a parameter that defines the maximum infused length, and this parameter will take into account the structure of the reinforcement, the resin viscosity, the fiber volume fraction and inlet geometry.     

Development of resin transfer molding process using scaling down strategy

The virtually developed resin transfer molding (RTM) manufacturing process for the large and complex composite part can be validated easily with the trial experiments on the scaled down mold. The scaling down strategy was developed using Darcy's law from the comparisons of mold fill time and mold fill pattern between full‐scale product and scaled down prototype. From the analysis, it was found that the injection pressure used in the scaled down mold should be the full‐scale injection pressure by the times of square of geometrical scale down factor, provided the identical injection strategy and raw material parameters were applied on both the scales. In this work, the RTM process was developed using process simulations for a large and complex high‐speed train cab front and it was validated by conducting experiments using a geometrically scaled down mold. The injection pressure as per the scaling down strategy was imposed on the scale downed high‐speed train cab front mold and a very close agreement was observed between the flow fronts of experimental and simulated results, which validates the scaling down strategy and the virtually developed RTM process for the full‐scale product. POLYM. COMPOS., 35:1683–1689, 2014. © 2013 Society of Plastics Engineers     

Flow-enhancing layers in the vacuum infusion process

The current trend towards increased use of vacuum infusion molding for large surface-area parts has increased the interest in an advanced modeling of the process. Because the driving pressure is limited to 1 atmosphere, it is essential to evaluate possible ways to accelerate the impregnation. One way of doing this is to use layers of higher permeability within the reinforcing stack, i.e. flow-enhancing layers. We present an experimental investigation of the flow front shape when using such layers. The through-thickness flow front was observed by making a number of color marks on the glass-mats forming the reinforcing stack, which became visible when the resin reached their position. The in-plane flow front was derived from observations of the uppermost layer. It turned out that existing analytical models agree very well with the experiments if effective permeability data is used, that is, permeability obtained from vacuum infusions. However, the fill-time was nearly twice as long as predicted from permeability data obtained in a stiff tool. This rather large discrepancy may be due to certain features of a flexible mold half and is therefore a topic for further research. The lead-lag to final thickness ratio is dependent on the position of the flow front and ranges form 5 to 10 for the cases tested. Interestingly the lead-lag has a miximum close to the inlet.     

Resin flow monitoring inside composite laminate during resin film infusion process

In this article, a novel method of measuring resin flow front under vacuum condition is presented. The in situ monitoring system with metal hollow probe based on gas flow balance can be used in resin film infusion (RFI) process, where resin film is used and transverse flow is dominated along thickness direction of fiber preform. The diameter of the probe was chosen to increase the measuring accuracy, and the reliability of the method was evaluated by comparison of visualization experiment. Experimental results demonstrate that the method is suitable for monitoring resin flow in RFI process with and without autoclave, and can obtain the information about resin filling time, nonuniform flow front, and the permeability of fiber preform. Furthermore, by means of the established monitoring system, the influences of pressure and lay‐up sequence of carbon fiber fabric on epoxy resin flow during RFI process were investigated. In addition, resin flow pattern with changing viscosity of epoxy resin was studied. POLYM. COMPOS., 35:681–690, 2014. © 2013 Society of Plastics Engineers     

Modeling of resin infusion in vacuum assisted resin transfer molding

Resin infusion was modeled and analytic solutions were obtained for vacuum assisted resin transfer molding (VARTM). Compaction behavior of the fiber preform was examined experimentally and the influence of compressibility of the preform on the resin infusion was investigated mathematically. Flow front advancement through the preform was predicted by the analytic model proposed in the present study. The model provided pressure and thickness distributions of the region impregnated by the resin. For verification of the analytic solutions, a resin infusion experiment and a mold filling simulation for VARTM were performed and compared with the analytic ones. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers.     

Experimental analysis and numerical modeling of flow channel effects in resin transfer molding

Composite manufacturing by Liquid Composite Molding (LCM) processes such as Resin Transfer Molding involve the impregnation of a net‐shape fiber reinforcing perform a mold cavity by a polymeric resin. The success of the process and part manufacture depends on the complete impregnation of the dry fiber preform. Race tracking refers to the common phenomenon occurring near corners, bends, airgaps and other geometrical complexities involving sharp curvatures within a mold cavity creating fiber free and highly porous regions. These regions provide paths of low flow resistance to the resin filling the mold, and may drastically affect flow front advancement, injection and mold pressures. While racetracking has traditionally been viewed as an unwanted effect, pre‐determined racetracking due to flow channels can be used to enhance the mold filling process. Advantages obtained through controlled use of racetracking include, reduction of injection and mold pressures required to fill a mold, for constant flow rate injection, or shorter mold filling times for constant pressure injection. Flow channels may also allow for the resin to be channeled to areas of the mold that need to be filled early in the process. Modeling and integration of the flow channel effects in the available LCM flow simulations based on Darcian flow equations require the determination of equivalent permeabilities to define the resistance to flow through well‐defined flow channels. These permeabilities can then be applied directly within existing LCM flow simulations. The present work experimentally investigates mold filling during resin transfer molding in the presence of flow channels within a simple mold configuration. Experimental flow frot and pressure data measurements are employed to experimentally validate and demonstrate the positive effect of flow channels. Transient flow progression and pressure data obtained during the experiments are employed to investigate and validate the analytical predictions of equivalent permeability for a rectangular flow channel. Both experimental data and numerical simulations are presented to validate and characterize the equivalent permeability model and approach, while demonstrating the role of flow channels in reducing the injection and mold pressures and redistributing the flow.     

Prediction of flow–induced process variables based on similarity analysis in the liquid molding process

In general, a numerical scheme is a widely accepted technique for estimating resin flow in the liquid molding process. A numerical mold filling analysis is essential to optimize the manufacturing process of a composite. However, finding an optimal condition from the numerical analysis requires many numerical calculations. The efforts can be greatly reduced if a similarity solution replaces the repeated numerical calculations. In this study, similarity relations are proposed to predict the flow‐induced process variables. such as resin pressure, resin velocity, and flow front evolution time, during mold filling. Numerical simulations are performed for two cases where a material property, an injection condition or a part shape is different. The model is verified by applying the similarity relation for two numerical results obtained from the thin shell structure.     

Flow front advancement during composite processing: predictions from numerical filling simulation tools in comparison with real‐world experiments

Liquid composite molding (LCM) techniques are innovative manufacturing processes for processing fiber reinforced polymer parts used e.g. for aerospace structures. Thereby the reinforcing material is placed in a mold and infiltrated with a low viscosity polymer matrix. Increasing production rates as well as part complexity lead to high production risks such as air inclusions or incomplete mold filling. Numerical mold filling simulations are promising tools enabling the composite manufacturing engineer to detect dry spots in the mold and find the optimal positions of the resin entry and ventilation system at an early process development stage. Today, different numerical models and software packages are available for modeling the flow through the reinforcing structure for visualization of the flow behavior. The goal of this study is the systematic comparison of two different software packages, namely PAM‐RTM^® and OpenFOAM. Both software tools are operated as they are commonly foreseen. Real world experiments under real process conditions are the basis for the assessment of the numerical predictions. The resin transfer molding (RTM) experiments are executed in a tool with a transparent upper mold half in order to see the flow front advancement. POLYM. COMPOS., 37:2782–2793, 2016. © 2015 Society of Plastics Engineers