Influence of textile parameters on the in‐plane permeability characteristics of non‐crimped fabric preforms

Material parameters such as the permeability of dry reinforcing textiles are key variables for modern composite production using liquid composite molding (LCM) technique. Nowadays numerical filling simulations are required for predicting the mold filling behavior. Inaccurate predictions can lead to a high risk of air inclusion and corresponding need for cost‐intense revision of the mold design. Permeability values of the textiles used in the process are basic requirements for a numerical filling simulation, since the permeability is directly linked to the filling behavior. Nevertheless, the permeability values of non‐crimped fabrics (NCF) which are used for aerospace and automotive structures are rare. In this study the influence of textile parameters of NCF on the in‐plane permeability has been investigated using a capacitive in‐plane permeability measurement technology. The results show the influence of the roving filament number as well as the used stitch length on the in‐plane permeability. It is confirmed that the textile grammage is not affecting the in‐plane permeability of NCF reinforcements. The results of this study are valuable for textile selection with specific permeability data as well as for numerical filling simulations. POLYM. COMPOS., 37:1854–1863, 2016. © 2015 Society of Plastics Engineers     

Tow impregnation during resin transfer molding of bi-directional nonwoven fabrics

A model has been developed for analyzing resin impregnation of fiber tows during resin transfer molding of bi-directional nonwoven fiber performs. The model is based on the existence of two main regions of resin flow: the macropore space formed among fiber tows and the micropore space formed among individual fiber filaments within a tow. The large difference in permeability between these two regions of flow leads to the potential for void formation during resin transfer molding. The model was formulated for both constant flow rate and constant pressure mold filling. For ambient pressure mold filling, the model predicts a difference in the size of the voids and distribution between axial tows (oriented along the flow direction) and transverse tows (oriented in the transverse direction). When vacuum is imposed on the mold, the model predicts the same resin impregnation behavior for both axial and transverse tows. Furthermore, given sufficient time, voids generated under vacuum mold filling will eventually collapse because of the absence of an opposing internal void pressure. In addition to insights on void formation, the model also provides a basis for the study of the relationship between resin transfer molding parameters and the resin impregnation process.     

A simple method for the measurement of compaction and corresponding transverse permeability of composite prepregs

Process simulation is of great importance in the development of processes for cost‐effective fabrication of composite structures, particularly for thermoset matrix composites. For the simulation of autoclave or hot press process, it requires knowledge of the compaction behavior and the saturated transverse permeability of fiber reinforcements. In this paper, a simple method without any sophisticated equipment is shown, which can simultaneously measure the compaction curve and the saturated transverse permeability as a function of fiber volume fraction. The method was used to measure the properties of S‐2 glass rovings and T700S carbon rovings prepregs. The effects of the impregnating fluid variety, the initial fiber volume fraction of prepreg, and the lay‐up type on the compaction behavior were investigated. The transverse permeability was also studied as a function of fiber content for various lay‐up types. The results indicate that Gutowski's compaction model and the modified Kozeny‐Carman equation proposed by Gutowski, which are important input parameters for the resin flow model, can be used to adequately fit the experimental data. POLYM. COMPOS. 28:61–70, 2007. © 2007 Society of Plastics Engineers     

Characterization of anisotropic permeability from flow front angle measurements

Textile permeability is a generally anisotropic material property, which characterizes the ease of establishing a resin flow through the fibrous reinforcement in Liquid composite molding (LCM) processes. Unidirectional injection experiments are commonly performed to determine in‐plane permeability. Effective permeability values have to be measured along three different textile directions to calculate the full in‐plane permeability tensor. This article presents a strategy to reduce the number of the required unidirectional experiments to two or even one by considering the angle that the flow front forms with the measurement direction. The relationship between this flow front angle and the permeability tensor elements was derived theoretically and verified by both simulations and experiments with various textile reinforcements. In addition, two methods were investigated to measure the flow front angle and the effective permeability during the experiments: a standard approach based on visual observations and a new method that relies on three pressure sensors, applicable also in the case of nontransparent tooling. The results show that: (I) the two methods provide consistent measurements and are substantially equivalent; (II) the strategy devised to characterize permeability by measuring the flow front angle is effective and accurate; (III) the proposed procedure allows reducing considerably the time and the material samples required for permeability characterization by unidirectional experiments. POLYM. COMPOS., 37:2037–2052, 2016. © 2015 Society of Plastics Engineers     

Effect of liquid characteristics on the wetting,capillary migration,and retention properties of fibrous polymer networks

Fluid penetration through porous networks consists of two different phenomena: (1) pore fluid displacement and (2) fluid flow through the pores. The first phenomenon depends on the pore size, the fluid–fluid interfacial tension, and the contact angle. The second phenomenon is pore‐size‐ and viscosity‐dependent. We adapted an experimental methodology often used for measurements of liquid permeability and hydraulic conductivity of soils and applied it to polymeric medical textiles. The methodology made use of a pressure/flow cell in which a sample was mounted. The flow rates were measured during sequences of increasing and decreasing pressures applied to the displacing nonwetting fluid (aqueous solution). The effects of the liquid parameters on penetration were investigated. Surface tension effects were studied with water and two solutions with surface tensions lower than that of pure water; the liquids with lower surface tensions had lower displacement pressures. To study viscosity effects, we used water and two solutions with viscosities higher than that of pure water. Increasing the viscosity not only caused the flow rate to decrease but also caused deformation, that is, enlargement, of the pores. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 97: 282–292, 2005     

吸胶膜对复合材料构件固化过程中树脂流动行为的影响

热固性树脂基复合材料构件成型过程中的树脂流动行为决定了其最终成型后的纤维体积分布情况,严重影响构件的最终成型质量。而吸胶膜作为预浸料中的多余树脂流出构件后的吸收载体,其材料特性对树脂的流动过程起主导作用。以吸胶膜为关注重点,基于AS4/3501-6复合材料体系,建立了厚截面复合材料构件在热压罐中固化压实的仿真模型,模型包括了固化反应、热传导和紧密压实三个模块。模型与实验中构件的压实情况对比,验证模型的可行性。通过模型计算结果研究了吸胶膜的孔隙率、渗透率及厚度等关键参数在压力、温度等工艺条件的协同作用下对树脂流动行为的影响规律。结果表明:吸胶膜的孔隙率和厚度作为吸收树脂载体的空间度量,对构件的最终压实厚度起主要作用;吸胶膜的渗透率通过树脂流动速度影响固化压实过程,渗透率过小时,构件的压实厚度明显减小。     

Experimental measurement of transversal micro‐ and macro permeability during compression molding of PP/Glass composites

In this work, a new experimental method is presented, aimed to measure the transversal permeability of fabric reinforcements for composite production. Through‐thickness impregnation of a glass woven fabric with polypropylene matrix was studied during compression molding experiments. The composite thickness was continuously measured during compression molding at different temperatures and pressure levels. The measured composite thickness was used to evaluate the molten front advancement during fabric impregnation. The existence of two different mechanisms of impregnation was highlighted by changes in the slope of the molten front advancement. Optical microscopy confirmed the occurrence of these two different mechanisms: macro‐scale impregnation, associated to void reduction between the bundles (inter‐bundle) occurring at lower times, and micro‐scale impregnation, associated to the flow of the matrix inside each bundle (intra‐bundle), occurring at longer times. Each of the two processes is characterized by a different value of the permeability, calculated according to Darcy law. The intra‐bundle and inter‐bundle permeability were used for calculating the transversal global permeability applying the Papathanasiou model. These values were compared with transversal permeability results evaluated using a low viscosity test fluid. POLYM. COMPOS., 35:105–112, 2014. © 2013 Society of Plastics Engineers     

Influence of sample thickness and measurement set-up on the experimental evaluation of permeability of metallic foams

The pressure drop measured when a fluid flow through a porous medium is presumed a linear function of the medium thickness along the flow direction. Recent works have, however, reported that such linear dependence is not valid for highly porous foams. The deviations observed were attributed to the relative contribution of entrance and exit effects on the total pressure drop. In this work, the effect of the measurement set-up and of the specimen thickness on the pressure drop was investigated. Permeability measurements were carried out with nickel-chromium foams. Two different set-ups for holding the samples were tested. Pressure drop vs. velocity curves were obtained with water at room temperature. The results obtained showed that the normalized pressure drop was affected by the specimen thickness and the set-ups used. The size of the annular section supporting the specimens has a clear influence on the magnitude of the deviation from the expected linear behavior between the pressure drop and the medium thickness. This effect has been attributed to the fluid diffusion and flow expansion into the annular region covered by the specimen support. The magnitude of this effect is more important as the thickness of the specimens increased. No significant entrance or exit effect was observed when the supporting annular section was minimized. The dispersion of permeability constants caused by this effect was determined and discussed.     

Apparent drag reduction phenomenon in the defluidized packed dense bed of the multisolid pneumatic transport bed

Experiments were performed to study the pressure drop behavior in the packed bed of dense particles in the multisolid pneumatic transport bed (MPTB). The packed bed under extensive analysis is established by fluidizing and then defluidizing the dense particle bed by increasing and then decreasing the air flow rate at a constant fine particle flow rate. The pressure drop in a packed bed established in this manner initially decreases significantly and then increases as the fine particle flow rate increases at a given air flow rate. This behavior signifies the apparent drag reduction phenomenon in the defluidized packed bed. The classical pressure drop equation by Ergun[1] was modified to account for this phenomenon.     

错流旋转填料床气相压降特性

旋转填料床的气相压降是旋转填料床应用和设计的一项重要指标。在气液两相错流流动条件下,利用空气-水系统对错流旋转填充床的气相压降进行分段模型化和实验研究。按照错流旋转填料床气体流动的路径将气相压降分为进口压降、填料层压降、集气段旋转动能转化压降和出气段压降。推导出压降与操作工况的关联式,其计算值与实测值吻合较好。实验表明错流旋转填料床的气相总压降与气体流量、旋转床转速、液体流量有关。在高转速和小气量的条件下,气相压降随气量增大先下降后上升;其他情况随气量增大而上升。错流旋转填料床气相压降随转速上升而下降,在小气量情况下转速对气相压降有明显影响。气相压降随进液量的增大而增大,当旋转填料床在低转速时进液量对气相压降有明显影响。     

Compaction of textile reinforcements for composites manufacturing. III: Reorganization of the fiber network

The objectives of this series of papers are to describe the mechanical behavior of textile reinforcements under normal load and to quantify the effects of diverse processing parameters on that behavior. In the first and second papers of the series, experimental compaction and relaxation results were reported; general trends were identified and the effects of changes in the processing parameters were analyzed. In this paper, the results of sequences of successive compaction cycles applied to dry textiles and to textiles saturated in distilled H₂O and silicone oil are presented. The reinforcements investigated are produced by assembling tows or rovings following different patterns; it is shown that the resulting heterogeneity, or regular variation of the local fiber volume fraction, can be associated to some particular elements of the mechanical behavior of the reinforcements. The reorganization of the fiber network and the effect of friction at the fiber contacts are demonstrated. Different stages in the reorganization process are identified; each stage is controlled by different parameters and corresponds to a precise behavior. Successive compaction cycles applied to a preform can reduce the void content of the final part.     

Compaction Behavior of Spray-Dried Alumina

Compaction behavior and resultant porosity of spray-dried alumina were examined over a range of pressures from 18 to 345 MPa. The variability in pressed density and pore size was measured as a function of spray-dried granule size, binder concentration, and powder moisture content. An exponential behavior was found between pressed density and compaction pressure, density increasing with the logarithm of the compaction pressure. Pore size also displays an exponential behavior, pore diameter decreasing with the log of increasing pressure. The distribution width about the median pore size was noted to decrease approximately in a log-log response to increasing compaction pressure. The behavior of the compaction and porosity curves is related to the degree to which the polymer binder is plasticized which, in turn, affects the pressure at which the spray-dried granules begin to crush. This apparent yield pressure, although dependent on amount of binder and powder moisture, is intrinsically dependent on the water/binder ratio. Finally, by analogy to soil mechanics, an empirical equation relating compact density, yield pressure, and slope is presented.     

Influence of Pressure on the Hydrodynamics and Mass Transfer Parameters of an Agitated Bubble Reactor

The present study deals with the pressure effects on the hydrodynamic flow and mass transfer within an agitated bubble reactor operated at pressures between 10⁵ and 100 × 10⁵ Pa. In order to clarify the flow behavior within the reactor, liquid phase residence time distributions (RTD) for different operating pressures and gas velocities ranging between 0.005 m/s and 0.03 m/s are determined experimentally by the tracer method for which a KCl solution is used as a tracer. The result of the analysis of the liquid‐phase RTD curves justifies the tank‐in‐series model flow for the operating pressure range. Good agreement is obtained between theoretical and experimental results assuming the reactor is operating as perfectly mixed. Two parameters characterizing the mass transfer are identified and investigated in respect to pressure: the gas‐liquid interfacial area and volumetric liquid‐side mass transfer coefficient. The chemical absorption method is used. For a given gas mass flow rate, the interfacial area as well as the volumetric liquid mass transfer coefficient decrease with increasing operating pressure. However, for a given pressure, a and k_La increase with increasing gas mass flow rates. The mass transfer coefficient k_L is independent of pressure.     

An Analysis of Pressure Drop and Holdup for Liquid‐Liquid Upflow through Vertical Pipes

The present study has attempted to investigate pressure drop and holdup during simultaneous flow of two liquids through a vertical pipe. The liquids selected were kerosene and water. The measurements were made for phase velocities varying from 0.05–1.2 m/s for both liquids. The pressure drop was measured with a differential pressure transducer while the quick closing valve (QCV) technique was adopted for the measurement of liquid holdup. The measured holdup and pressure drop were analyzed with suitable theoretical models according to the existing flow patterns. The analysis reveals that the homogeneous model is suitable for dispersed bubbly flow whereas bubbly and churn‐turbulent flow pattern is better predicted by the drift flux model. On the other hand, the two fluid flow model accurately predicts the pressure drop in core annular flow.     

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.     

Multistage rotor‐stator spinning disc reactor

The scale up of a rotor‐stator spinning disc reactor by stacking single stage rotor‐stator units in series is demonstrated. The gas‐liquid mass transfer per stage is equal to the mass transfer in a single stage spinning disc reactor. The pressure drop per stage increases with increasing rotational disc speed and liquid flow rate. The pressure drop is more than a factor 2 higher for gas‐liquid flow than for liquid flow only, and is up to 0.64 bar at 459 rad s^?1. The high mass and heat transfer coefficients in the (multistage) rotor‐stator spinning disc reactor make it especially suitable for reactions with dangerous reactants, highly exothermic reactions and reactions where selectivity issues can be solved by high mass transfer rates. Additionally, the multistage rotor‐stator spinning disc reactor mimics plug flow behavior, which is beneficial for most processes. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

Effect of pressure drop on performance of hollow-fiber membrane module for gas permeation

The pressure drop mainly due to viscous friction inside hollow fibers is taken into consideration by nondimensionalization and numerical simulation of governing equations. For pure gas, the permeation pressure and velocity of actual situations with a viscous fluid deviate significantly from those of the corresponding inviscid or no-pressure-drop cases. The apparent permeability estimated from the relation of permeate flow rate and pressure difference is considerably underestimated in actual situations, and more severely for the region of small pressure difference and large module length. Numerical simulation shows that the estimated permeability behaves as if it were an increasing function of pressure difference for a constant permeability and roughly a constant for a dual-sorption-type permeability, respectively. For binary-mixture permeation the cut ratio and purity of permeate stream are mainly governed by two dimensionless parameters standing for pressure drop and permeability, respectively. The cut ratio and corresponding product composition are predictable without the rigorous simulation of the governing equations.     

Permeability of soft porous media under one-dimensional compaction

A novel experimental approach to measure permeability of porous material samples under variable longitudinal compaction has been developed. The material has a non-linear structural behavior and exhibits a small hysteresis during mechanical loading and unloading experiments. The new permeameter includes a piston moving inside a Plexiglas cylinder with controllable speed and a test section where the porous material sample is placed under compaction by two grids with adjustable positions. Time-dependent pressure was recorded at four different locations along the sample together with the velocity of the piston. Experiments with two different sample lengths have been performed at three different Reynolds numbers based on the apparatus diameter. The results show that pressure gradient and permeability data do not depend on initial uncompacted sample length. All experiments included measurements at various compaction ratios of the material followed by measurements during relaxation/expansion of the material. No hysteresis was observed in the pressure gradient and permeability data during compaction and expansion of the material for a wide range of compaction ratio. The effects of small velocity fluctuations due to variable friction of the moving piston with cylinder’s wall were also considered. These velocity fluctuations cause pressure fluctuations within the sample which are high close to the inlet part of the material sample and are reduced almost completely towards its outlet. However these pressure fluctuations when scaled with the corresponding mean pressure retained their time-dependent amplitude and phase unchanged along the material. These relative pressure fluctuations cancelled out the flow velocity fluctuations resulting insignificant fluctuations in permeability. It was found that permeability, which is a material property, is drastically reduced with increased compaction ratio of the material while its solid fraction changes substantially but its porosity remains practically unchanged. A comparison with the Cármán–Kozeny expression for random porous media was also examined. Cármán–Kozeny expression predicts qualitatively the reduction of permeability with compaction. However, the predicted values of permeability are very sensitive to the initial value of porosity.     

Model Development of the Transient Solid Hold‐up and Pressure Drop in Fabric Filters

There are different non‐idealities related to cloth filters, which are cleaned by jet pulses. The well‐known phenomenon of cake compaction causes progressive curves of the pressure drop versus time. Some experiments show degressive shapes of the pressure drop, though. It will be shown, that this behavior can be explained by dividing the filter in segments. Each model segment can have a different cake thickness, whereas the pressure drop of every single segment is the same at any time during filtration. The capacity of this model is pointed out to determine the cake load on existing filters and to simulate unknown operating points.