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.     

A dual-scale analysis of macroscopic resin flow in vacuum assisted resin transfer molding

In Vacuum Assisted Resin Transfer Molding (VARTM) where a sacrificial medium is used to facilitate the resin flow, the velocity of the resin varies drastically between inside the sacrificial medium and inside the fiber preform. Although the thickness-to-length ratio of a VARTM product is usually small, a 3-D analysis is required for analyzing the lead-lag flow in the two different media. The problem associated with the full 3-D analysis is the CPU time. A full 3-D numerical mesh comprising a large number of nodes requires a CPU time impractical on most computer platforms. In this study, a dual-scale analysis technique was proposed. First, the flow analysis for the entire calculation domain was conducted in 2.5-D. Using the results of the 2.5-D calculation, the 3-D analysis was performed for a small area of special concern. In some numerical examples, the local 3-D analysis could discover an eccentric flow pattern as well as the lead-lag flow that would inevitably be neglected in 2.5-D simulations. The global-local analysis technique practiced in this study can be used to analyze the intricate flow of resin through non-uniform media in affordable CPU times. Polym. Compos. 25:510–520, 2004. © 2004 Society of Plastics Engineers.     

1,4-Bis(2,3-dicarboxyl-phenoxy)benzene dianhydride-based phenylethynyl terminated thermoset oligoimides for resin transfer molding applications

A series of thermoset oligoimides have been prepared by the thermal polycondensation of 1,4-bis(2,3-dicarboxyl-phenoxy)benzene dianhydride with three different aromatic diamines in the presence of 4-phenylethynylphthalic anhydride as an end capping reagent. The aromatic diamines included 4,4′-oxydianiline, 2,2′-bis(trifluoromethyl)benzidine (TFDB) and 2-phenyl-4,4′-diaminodiphenyl ether (p-ODA). Effects of the chemical structures and molecular weights of the oligoimides on their aggregated structures, melt processability as well as the thermal and mechanical properties of the cured films were then systematically investigated. X-ray diffraction results indicated that ODA series oligoimides and TFDB series oligoimides showed crystallinity; however, the asymmetrical p-ODA enables the p-ODA series oligoimides to exhibit amorphous forms. So the p-ODA based oligoimides with molecular weight of 750 g mol⁻¹ showed much lower melt viscosity at a low temperature and the melt viscosity could maintain below 1 Pa s⁻¹ after isothermal aging for 2 h at any temperature in the range of 220–280 °C by rheological measurements. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 47967.     

Automation of the vacuum assisted resin transfer molding process for recreational composite yachts

The use of glass fiber reinforced plastics (GFRP) in large primary marine structures has noticeably increased due to their favorable stiffness, strength, durability, and manufacturability. However, GFRP construction can become cost‐prohibitive at the superyacht‐scale (36–60 m) as defects and labor intensiveness increase. In this paper, we presented an automated vacuum assisted resin transfer molding process (VaRTM) that can be integrated into an existing setup for manufacturing recreational composite yachts in the 49‐meter range. The objective of automating the system is to reduce defects and labor intensity. The developed automation system consisted of a controller, resin supply lines with valves, and infrared sensors. The control software, valves and sensors were custom developed. The system automatically monitors and adjusts resin flow in the mold in real‐time to mitigate flow front variations. The system was used to run three different scenarios common in marine composites manufacturing using VaRTM; a flat plate with consistent ply sequence, a flat plate with varying ply sequence, and a scaled yacht keel section. Results indicated that use of the automated setup improved overall evenness of resin flow and limited unwanted convergence compared to the traditional manual setup. Tensile testing indicated similar mechanical performance but greater variation in the manual sample. Voids were discovered in regions of flow convergence of the manual panel and reflected slightly more varied tensile properties as compared to automated panels. POLYM. COMPOS., 38:2411–2424, 2017. © 2015 Society of Plastics Engineers     

Elevated‐temperature vacuum‐assisted resin transfer molding process for high performance aerospace composites

Vacuum‐assisted resin transfer molding (VARTM) is commonly used for general temperature applications (<150 °C) such as boat hulls and secondary aircraft structures. With growing demands for applications of composites in elevated temperature environments, significant cost savings can be achieved by employing the VARTM process. However, implementation of the VARTM process for fabricating elevated temperature composites presents unique challenges such as high porosity and low fiber volume contents. In the present work, a low cost and reliable VARTM process is developed to manufacture elevated temperature composites for aerospace applications. Modified single vacuum bagging infusion and double vacuum bagging infusion processes were evaluated. Details of the method to obtain high quality composite parts and the challenging issues related to the manufacturing process are presented. Density and fiber volume fraction testing of manufactured panels showed that high quality composite parts with void content less than 1% have been consistently manufactured. A property database of the resin system and the composites was developed. A three‐dimensional mathematical model has also been developed for flow simulation and implemented in the ABAQUS finite element package code to predict the resin flow front during the infusion process and to optimize the flow parameters. The results of the present study indicate that aircraft grade composite parts with high fiber volume fractions can be manufactured using the developed elevated temperature VARTM process. © 2013 Society of Chemical Industry     

Development of epoxy/hyperbranched blends for resin transfer molding and vacuum assisted resin transfer molding applications: Effect of a reactive diluent

The rheological and thermomechanical properties of some epoxy blends modified with hyperbranched polymers are reported. The effects of different percentages of a multifunctional reactive diluent were investigated to develop formulations that could be processed by RTM (Resin Transfer Molding) and VARTM (Vacuum‐Assisted Resin Transfer Molding). The diluent chosen for the study was trimethylolpropane triglycidyl ether, which was added at three percentages: 10%, 20%, and 40%. The hyperbranched modifier used was aliphatic polyester of the fourth pseudo‐generation commercialized by Perstorp as Boltorn? H40. A cure cycle composed of a precure at 135°C followed by a postcure at 180°C was adopted. The blends were thoroughly characterized in both the unreacted and cured states. The unreacted blends were characterized by parallel plate rheometry, both in dynamic and isothermal mode. Analysis of the cured samples was carried out through dynamic mechanical tests after precuring and postcuring. The diluent had an impact, due to its peculiar structure, on both the uncured and cured properties. POLYM. ENG. SCI., 2009. © 2009 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.     

Vacuum‐assisted resin transfer molding model

A model of the vacuum‐assisted resin transfer molding (VARTM) process is developed that includes the most important aspects of the processing physics. The model consists of several submodels, such as preform mechanics, Darcy flow, wicking flow, and void formation. The preform mechanics model treats the preform as a linearly elastic, one‐dimensional (1D) solid. However, the key physical process is the lubrication of the preform due to fluid wetting, and this is modeled as a reduction in preform modulus, an easily measurable parameter. Residual stress, three‐dimensional (3D) structural behavior, and nonlinearity are neglected, but can all be included. The fluid flow model of capillary wicking is not tacked onto the Darcy equation as a modified boundary condition, as was previously done. The wicking is treated simply, but more realistically, by performing a force balance on the fluid in a pore. Balancing the capillary pressure and the viscous drag allows the development of a wicking front that precedes the main Darcy flow front to an extent that depends on several easily measurable factors. It is this wicking front that is responsible for the small void formation that reduces the quality of VARTM parts, relative to resin transfer molding (RTM) parts. POLYM. COMPOS. 26:477–485, 2005. © 2005 Society of Plastics Engineers     

Multiscale fiber‐reinforced composites prepared by vacuum‐assisted resin transfer molding

Carbon nanotube (CNT)/aramid fiber epoxy composites were produced using a new manufacturing method proposed in this study. The rheological and morphological experiments of the CNT/PEO nanocomposites indicates that the PEO nanocomposites have a good dispersion state of the CNTs. The flexural mechanical properties of the aramid fiber/CNT epoxy composites were measured. The CNTs dispersed in the epoxy resin between the aramid fibers were observed using field emission scanning electron miscroscope (FESEM). It was found that the flexural properties of the multiscale fiber‐reinforced composites were higher than those of aramid fiber/epoxy composites. POLYM. COMPOS., 28:458–461, 2007. © 2007 Society of Plastics Engineers.     

Flow modeling and simulation for vacuum assisted resin transfer molding process with the equivalent permeability method

Vacuum assisted resin transfer molding (VARTM) offers numerous advantages over traditional resin transfer molding, such as lower tooling costs, shorter mold filling time and better scalability for large structures. In the VARTM process, complete filling of the mold with adequate wet-out of the fibrous preform has a critical impact on the process efficiency and product quality. Simulation is a powerful tool for understanding the resin flow in the VARTM process. However, conventional three-dimensional Control Volume/Finite Element Method (CV/FEM) based simulation models often require extensive computations, and their application to process modeling of large part fabrication is limited. This paper introduces a new approach to model the flow in the VARTM process based on the concept of equivalent permeability to significantly reduce computation time for VARTM flow simulation of large parts. The equivalent permeability model of high permeable medium (HPM) proposed in the study can significantly increase convergence efficiency of simulation by properly adjusting the aspect ratio of HPM elements. The equivalent permeability model of flow channel can simplify the computational model of the CV/FEM simulation for VARTM processes. This new modeling technique was validated by the results from conventional 3D computational methods and experiments. The model was further validated with a case study of an automobile hood component fabrication. The flow simulation results of the equivalent permeability models were in agreement with those from experiments. The results indicate that the computational time required by this new approach was greatly reduced compared to that by the conventional 3D CV/FEM simulation model, while maintaining the accuracy, of filling time and flow pattern. This approach makes the flow simulation of large VARTM parts with 3D CV/FEM method computationally feasible and may help broaden the application base of the process simulation. Polym. Compos. 25:146–164, 2004. © 2004 Society of Plastics Engineers.     

Carbon nanotube/epoxy composites fabricated by resin transfer molding

Carbon nanotube (CNT)/epoxy composites with controllable alignment of CNTs were fabricated by a resin transfer molding process. CNTs with loading up to 16.5 wt.% were homogenously dispersed and highly aligned in the epoxy matrix. Both mechanical and electrical properties of the CNT/epoxy composites were dramatically improved with the addition of the CNTs. The Young’s modulus and tensile strength of the composites reach 20.4 GPa and 231.5 MPa, corresponding to 716% and 160% improvement compared to pure epoxy. The electrical conductivity of the composites along the direction of the CNT alignment reaches over 1 × 10⁴ S/m.     

Vacuum‐assisted resin transfer molding using tackified fiber preforms

A low cost composite fabrication process—tackified SCRIMP—is described for fabricating aerospace‐grade composites based on tackification and vacuum‐assisted resin transfer molding (VARTM). Tackification based on a commercial tackifier (FT 500 from 3M) was used to make the net‐shape fiber preform. It was found that tackifier concentration and application conditions play important roles in governing the moldability of tackified fiber preforms. An epoxy resin (PR 500 from 3M) was used in the VARTM process‐SCRIMP at high temperatures. Experimental results show that composites with high fiber content (> 60% by volume) can be manufactured at low cost using tackification. Effects of tackification methods on composite dimension control, void content and mechanical properties were investigated and compared in both RTM and SCRIMP.     

Modeling resin transfer molding of polyimide (PMR-15)/fiber composites

Polyimide (PMR-15)/fiber composites are important structural components in many high temperature applications requiring high performance lightweight materials. Most composites are fabricated from “prepregs,” but resin transfer molding (RTM) is an alternative route to the formation of a resin-saturated perform, further processing of which yields the final part. A simple model is proposed for the RTM of “thin” composite parts. Numerical solution of the model is accomplished through integration of the equation s formulated using he finite element method. This approach accounts for the changing shape of the flow front during RTM. The resulting computational schemes are numerically stable and efficient.     

One‐dimensional heat transfer study of a fiber‐reinforced wind epoxy composite system in vacuum assisted resin transfer molding process

To investigate the influence of curing behavior of a wind‐epoxy resin in vacuum assisted resin transfer molding (VARTM) process, numerical analysis of the heat transfer study of VARTM process was established to characterize temperature distribution in one dimension by directly solving heat equation and was compared with the result of experiment. Differential scanning calorimeter (DSC) was applied to test curing kinetic parameters of the epoxy system, which was required to evaluate internal thermal source and analyze heat transfer equations. Two models, such as nth order curing model and autocatalytic model, were established to solve the heat transfer equation. Combining the theoretical results with nth order curing model and experiment, it can be known that in early stage, temperature distribution correlates well with the experiment results due to the dominant chemical‐controlled reaction, while great discrepancy appears in the latter stage due to diffusion‐controlled reaction taking over. The result of the heat equation solved by autocatalytic model correlates well with the experiment results. POLYM. COMPOS., 35:1031–1037, 2014. © 2013 Society of Plastics Engineers     

A prediction method on in‐plane permeability of mat/roving fibers laminates in vacuum assisted resin transfer molding

Vacuum assisted resin transfer molding (VARTM) is one of the promising manufacturing techniques for large‐scaled composite components with complex geometry, such as yachts or fishing vessels. To reduce the failure risk of production, numerical simulation of resin infusion process before manufacture is helpful. In general, basic characteristics of perform, such as permeability, need to be measured by experiments in practice. However, this experimental approach sometimes may be costly because specific types of fibers as well as preform with different layer numbers need individual experiments. This study first introduces the experimental procedure of measuring the permeability of reinforcements via Darcy's Law. On the basis of experimental observation of permeability of different layer order, we assumed that the change of the permeability in different experiments is mainly affected by the space provided by the fiber. Accordingly, an efficient prediction method based on the idea of “total porous space of the reinforcement” is proposed. It is shown that this method can give reference between prediction and experiments of the mat/roving fiber preform. Though the resin flowing is complex, this prediction gives a simple, macroscopic reference way for the injection characteristic of large‐sized ships, and consequently facilitates the numerical design work of composite structures manufactured by VARTM technique. POLYM. COMPOS., 27:665–670, 2006. © 2006 Society of Plastics Engineers     

Capillary effects in vacuum‐assisted resin transfer molding with natural fibers

The study of the capillary flow developed during the processing of composite materials is key because it acts as an important driving force for the impregnation of the fiber tows. It is also the main mechanism of void formation during infiltration of the fibers. In this work, capillary pressure of jute/vinylester composites was measured and the impact of capillary forces on fabric permeability was analyzed. It was found that the capillary pressure was significantly higher in vegetal than in synthetic fiber fabrics. In addition, the permeability of the fibers was characterized using various fluids. The resulting permeability was influenced by the nature of fluid and its polar property. Finally, the capillary pressure measured by this work was used to correct the experimental permeability in order to obtain a property independent of the test fluid. POLYM. COMPOS., 2012. © 2012 Society of Plastics Engineers     

Mechanical and dynamic mechanical analysis of hybrid composites molded by resin transfer molding

This work aims to evaluate the performance of glass/sisal hybrid composites focusing on mechanical (flexural and impact) and dynamic mechanical analyses (DMTA). Hybrid composites with different fiber loadings and different volume ratios between glass and sisal were studied. The effect of the fiber length has also been investigated. The densities of the composites were compared with the theoretical values, showing agreement with the rule of mixtures. The results obtained in the flexural and impact analysis revealed that, in general, the properties were always higher for higher overall reinforcement content. By DMTA, an increase in the storage and loss modulus was found, as well as a shift to higher values for higher glass loading and overall fiber volume. It was also noticed an increase in the efficiency of the filler and the calculated activation energy for the relaxation process in the glass transition region. The fiber length did not significantly change the results observed in all analyses carried out in this work. The calculated adhesion factor increased for higher glass loadings, meaning the equation may not be applied for the system studied and there are other factors, besides adhesion influencing energy dissipation of the composites. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Void transport in resin transfer molding

The transport of single drops through a hexagonal cylinder array is used to study the void movement and deformation in a resin transfer molding process. A transparent flow cell is used to visualize the transport of voids through a porous media model. Experiments are conducted with nearly inviscid water drops and viscous glycerol drops with drop sizes ranging from 0.4 to 80 μl, and with both a Newtonian fluid and Boger fluid with average resin velocities ranging from 0.011 to 0.140 cm/s. Two critical capillary numbers, which determine the breakup (Ca_b) and mobilization (Ca*) of drops, are measured to better understand the flow dynamics of voids. As demonstrated by the experiments, there is a critical drop size, below or above which a quite different flow behavior is observed. Such a transition is analyzed with consideration of the geometry characters in the flow field. Results expand the former studies in this area to a significantly larger range of drop sizes and capillary numbers. Particle Tracking Velocimetry is also used to quantify the local velocity, shear stress, extensional stress and energy dissipation in the flow field. Polym. Compos. 25:417–432, 2004. © 2004 Society of Plastics Engineers.     

Thermal dispersion in resin transfer molding

This investigation focuses on the effects of thermal dispersion in resin transfer molding (RTM). A set of volume-average balance equations suitable for modeling mold filling in RTM is described and implemented in a numerical mold filling simulation. The energy equation is based on the assumption of local thermal equilibrium and includes a dispersion term. Thermal dispersion is an enhanced transport of heat due to local fluctuations in the fluid velocity and temperature away from their average values. Nonisothermal mold filling experiments are performed on a center-gated disk mold to investigate and quantify dispersion effects. Good agreement is found between the experimentally measured and numerically predicted temperatures, and a function for the transverse dispersion coefficient in a random glass fiber mat is determined. The results indicate that thermal dispersion is important in RTM processes and must be included in simulations to obtain accurate predictions.