Investigations on pressure and thickness profiles in carbon fiber-reinforced polymers during vacuum assisted resin transfer molding

Systematic experiments have been carried out by monitoring the in-situ pressure and thickness profiles for three different configurations, viz., flat plate, flat plate with a central circular hole, and an L-section using vacuum assisted resin transfer molding (VARTM) process. The effect of anisotropy on resin flow has been quantified by considering uni-directional carbon fiber preforms with 0 degrees and 90 degrees orientation to the flow direction for each configuration. A quasi-isotropic 45 degrees/0 degrees/-45 degrees/90 degrees](S) layup has also been included for flat plate case. Additionally, the study has been extended to understand the effect of using high permeability medium for each configuration. Fluid pressure profiles and thickness variation profiles have been obtained using an array of pressure sensors and linear variable differential transformers for each configuration. Experimental data reveal that anisotropy (due to changing fiber orientations), configuration, and gravity significantly change fluid pressure and displacement fields obtained during VARTM.

Enhancements of the simulation method on the edge effect in resin transfer molding processes

In resin transfer molding processes, small clearances exist between the fiber preform and the mold edges, which result in a preferential resin flow in the edge channel and then disrupt the flow patterns during the mold filling stage. A mathematical model including the effect of cavity thickness on resin flow was developed for flow behavior involving the interface between an edge channel and a porous medium. According to the mathematical analysis of momentum equations in a fully developed rectangular duct and formulations of the equivalent edge permeability, comparing with three-dimensional Navier-Stokes equations, the governing equations were modified in the edge channel. The volume of fluid (VOF) method was applied to track the flow front. A simple case is numerically simulated using the modified governing equations. The effects of edge channel width and cavity thickness on flow front and inlet pressure are analyzed, and the evolution characteristics of simulated results are in agreement with the experimental results. (c) 2007 Elsevier B.V. All rights reserved

Reactive Mold Filling in Resin Transfer Molding Processes with Edge Effects

Reactive mold filling is one of the important stages in resin transfer molding processes, in which resin curing and edge effects are important characteristics. On the basis of previous work, volume-averaging momentum equations involving viscous and inertia terms were adopted to describe the resin flow in fiber preform, and modified governing equations derived from the Navier-Stokes equations are introduced to describe the resin flow in the edge channel. A dual-Arrhenius viscosity model is newly introduced to describe the chemorheological behavior of a modified bismaleimide resin. The influence of the curing reaction and processing parameters on the resin flow patterns was investigated.

Mesoscopic simulation of the impregnating process of unidirectional fibrous preform in resin transfer molding

The resin transfer molding has gained popularity in the preparation of fiber-reinforced polymer-matrix composites because of its high efficiency and low pollution. The non-uniform inter-tow and intra-tow flows are regarded as the reason of void formation in RTM. According to the process characteristics, the axisymmetric model was developed to study the interaction between the flow in the inter-tow space and that in the intra-tow space. The flow behavior inside the fiber tows was formulated using Brinkman's equation, while that in the open space around the fiber tows was formulated by Stokes' equation. The volume of fluid (VOF) method was applied to track the flow front, and the effects of filling velocity, resin viscosity, inter-tow dimension and intra-tow permeability on fluid pressure and flow front were analyzed. The results show that the flow front difference between the inter-tow and intra-tow becomes larger with the decrease of intra-tow permeability, as well as the increase of filling velocity and inter-tow dimension.

Tricot stitched carbon fiber reinforced polymer composite laminates manufactured by resin transfer molding process: C-scan and flexural analysis

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

The effect of 3D weaving and consolidation on carbon fiber tows, fabrics, and composites

This article investigates the damage imparted on load-bearing carbon fibers during the 3D weaving process and the subsequent compaction behavior of 3D woven textile preforms. The 3D multi-layer reinforcements were manufactured on a textile loom with few mechanical modifications to produce preforms with fibers orientated in the warp, weft, and through-the-thickness directions. Tensile tests were conducted on three types of commercially available carbon fibers, 12k HTA, 6k HTS, and 3k HTS in an attempt to quantify the effect of fiber damage induced during the 3D weaving process on the mechanical and physical performance of the fiber tows in the woven composite. The tests were conducted on fiber tows sampled from different locations in the manufacturing process from the bobbin, through the creel and loom mechanism, to the final woven fabric. Mechanical and physical testing were then conducted to quantify the tow geometry, orientation and the effect of compaction during manufacture of two styles of 3D woven composite by vacuumassisted resin transfer molding (VaRTM).

Estudo comparativo de pás para aerogeradores de grande porte fabricadas em materiais compósitos reforçadas com fibra de carbono ou fibra de vidro

The research and development of wind turbine blades are essential to keep pace with worldwide growth in the renewable energy sector. Although currently blades are typically produced using glass fiber reinforced composite materials, the tendency for larger size blades, particularly for offshore applications, has increased the interest on carbon fiber reinforced composites because of the potential for increased stiffness and weight reduction. In this study a model of blade designed for large generators (5 MW) was studied on a small scale. A numerical simulation was performed to determine the aerodynamic loading using a Computational Fluid Dynamics (CFD) software. Two blades were then designed and manufactured using epoxy matrix composites: one reinforced with glass fibers and the other with carbon fibers. For the structural calculations, maximum stress failure criterion was adopted. The blades were manufactured by Vacuum Assisted Resin Transfer Molding (VARTM), typical for this type of component. A weight comparison of the two blades was performed and the weight of the carbon fiber blade was approximately 45% of the weight of the fiberglass reinforced blade. Static bending tests were carried out on the blades for various percentages of the design load and deflections measurements were compared with the values obtained from finite element simulations. A good agreement was observed between the measured and calculated deflections. In summary, the results of this study confirm that the low density combined with high mechanical properties of carbon fibers are particularly attractive for the production of large size wind turbine blades

Fractography analysis and fatigue strength of carbon fiber/RTM6 laminates

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Carbon fiber non-crimp multi-axial reinforcement and epoxy mono-component system composite: fatigue behavior

Fiber reinforced polymer composites have been widely applied in the aeronautical field. However, composite processing, which uses unlocked molds, should be avoided in view of the tight requirements and also due to possible environmental contamination. To produce high performance structural frames meeting aeronautical reproducibility and low cost criteria, the Brazilian industry has shown interest to investigate the resin transfer molding process (RTM) considering being a closed-mold pressure injection system which allows faster gel and cure times. Due to the fibrous composite anisotropic and non homogeneity characteristics, the fatigue behavior is a complex phenomenon quite different from to metals materials crucial to be investigated considering the aeronautical application. Fatigue sub-scale specimens of intermediate modulus carbon fiber non-crimp multi-axial reinforcement and epoxy mono-component system composite were produced according to the ASTM 3039 D. Axial fatigue tests were carried out according to ASTM D 3479. A sinusoidal load of 10 Hz frequency and load ratio R = 0.1. It was observed a high fatigue interval obtained for NCF/RTM6 composites. Weibull statistical analysis was applied to describe the failure probability of materials under cyclic loads and fractures pattern was observed by scanning electron microscopy. (C) 2010 Published by Elsevier Ltd.

Evaluation of stitched fabric composite processed by RTM in quasi-static test

Stitched fabrics have been widely studied for potential application in aircraft structures since stitch yarns offer improvements in the out-of-plane mechanical properties and also can save time in the lay up process. The down side of stitch yarns came up in the manufacturing process of fabric in which defects introduced by the needle movement creating fiber-free-zones, fiber breakage and misalignment of fibers. The dry stitched carbon fabric preform has mainly been used in the Resin Transfer Molding (RTM) process which high fiber content is aimed, those defects influence negatively the injection behavior reducing the mechanical properties of final material. The purpose of this research work focused on testing in quasi-static mechanical mode (in-plane tension) of a monocomponent resin CYCOM (R) 890 RTM/carbon fiber anti-symmetric quadriaxial fabric stitched by PE 80Dtex yarn processed by RTM. The evaluation consisted in comparing the scatter of the quasi-static test with the attenuation of ultrasonic maps, which show the path of the resin and possible dry spots considering that interference of yarn in resin flow is detectable in ultrasonic measurement. Microscopic analysis was also considered for further evaluation in case of premature failure. (C) 2011 Published by Elsevier Ltd. Selection and peer-review under responsibility of ICM11

Influence of voids on the flexural resistance of the NCF/RTM6 composites

A major difficulty to achieve maximum weight savings in the manufacture of composite structural components, is the tendency of these materials have the formation of voids and cracks in the interior and surface components. In aeronautical applications, controlling the volume fraction of fibers, resins and empty the components of composite is very hard. In this work, composites of epoxy matrix RTM6 reinforced with NCF (non crimp fabric carbon) processed by resin transfer molding (RTM) were characterized for porosity (P-ap) and density (rho(ad)). We used a method based on Archimedes' principle (ASTM C830) and the technique of helium pycnometer. The porosity values were compared with those determined by acid digestion (ASTM D3171). The mechanical properties of processed composites was evaluated by testing on the performing flexural and the results were correlated with the porosity value. All techniques tested to determine void content are satisfactory. The differents results can be justified for heterogeneous void distribution on laminate and differences among techniques characteristics. (C) 2011 Published by Elsevier Ltd. Selection and/or peer-review under responsibility of ICM11

Effect of fiber surface on flexural strength in carbon fabric reinforced epoxy composites

The effect of carbon fiber surface characteristics on flexural properties of structural composites is studied in this work. Two types of intermediate modulus carbon fibers were used: T800HB and IM7. Results revealed that higher mechanical properties are linked with higher interfacial adhesion. Morphologies and chemical compositions of commercial carbon fibers (CF) were characterized by Fourier Transformed Infra Red (FTIR) and Scanning Electronic Microscopy (SEM). Comparing the results, the T800HB apparently has more roughness, since the IM7 seems to be recovered for a polymeric film. On other hand, the IM7 one shows higher interactivity with epoxy resin system Cycom 890 RTM. Composites produced with Resin Transfer Molding (RTM) were tested on a flexural trial. Interfacial adhesion difference was showed with SEM and Dynamic Mechanical Analyses (DMA), justifying the higher flexural behavior of composites made with IM7 fibers. © 2013 Elsevier B.V. All rights reserved.

A influência do processo de cura nas propriedades do compósito estrutural carbono/epóxi fabricado via VARTM: processamento e caracterização

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Compósito estrutural carbono/epóxi via RTM para aplicação aeronáutica: processamento e caracterização

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Influência dos parâmetros de processamento por RTM no volume de vazios em compósitos carbono/epóxi

Pós-graduação em Engenharia Mecânica - FEG