Papers by Keyword: RTM

Abstract: Fiber-metal-laminates (FML) provide excellent fatigue behavior, damage tolerant properties, and inherent corrosion resistance.To speed up manufacturing and simultaneously increase the geometrical complexity of the produced FML parts, Mennecart et al. proposed a new single-step process combining deep-drawing with infiltration (HY-LCM). Although the first experimental results are promising, the process involves several challenges, mainly originating from the Fluid-Structure-Interaction (FSI) between deep-drawing and infiltration. This work aims to investigate those challenges to comprehend the underlying mechanisms. A new close-to-process test setup is proposed on the experimental side, combining deep-drawing of a hybrid stack with a linear infiltration. A process simulation model for FMLs is presented on the numerical side, enabling a prediction of the dry molding forces, local Fiber Volume Content (FVC) within the three glass fiber (GF) interlayers, and simultaneous fluid progression. The numerical results show that the local deformation of the hybrid stack and required forces are predictable. Furthermore, lateral sealing of the hybrid stacks leads to deviations from the intended initially one-dimensional fluid progression. Eventually, the numerical results demonstrate that most flow resistance originates from geometrically critical locations. Future experimental and numerical work will combine these insights to focus on the flow evaluation during deformation and a successful part-level application.

Abstract: Compression resin transfer molding using inflatable seals is a new variant of LCM (“Liquid composite molding”) processes, which uses the inflatable seals to compress the fiber reinforcements and drive the resin to impregnate the fabric preform, resulting to fill the entire mold cavity. During resin injection, the preform is relaxed. Consequently, the resin enters easily and quickly into the mold cavity. After, the necessary resin is injected into the mold cavity, the compression stage takes place, in a stepwise manner, by swelling the inflatable seals. The objective of this paper is to present this new process and study the effect of the number of inflatable seals on the filling time.

Abstract: This work aims to numerically simulating the resin injection manufacturing process of a polymer composite,reinforced with ribbons of NiTishape memory alloy, using the software Ansys CFX^®. The multiphase flow mathematical modeling was used to describe the transient and isothermal resin-air flow during the process. Results of the pressure fields, velocity andvolume fractionsof the involved phases are presented. The fluid flow inside the mold was compared withthe flow between parallel flat plates and showed to be consistent. Process parameters, such as resin volumetric flow rate, resin inlet and air outlet positions have a large influence in the mold filling time, volume and position of voids fractions inside de mold and final product quality.

Abstract: The objective of this work is to describe the fluid flow in porous media including the sorption term of the fluid by the fibers. The study has been applied to the manufacture of fiber-reinforced polymer composites by resin transfer molding, giving emphasis to radial resin infiltration in a one-dimensional approach. The mass conservation equation and Darcy’s law are presented and the solution of the governing equation is obtained. The advanced mathematical modeling includes the effect of fluid sorption by the porous media. Predicted flow front results and resin pressure fields within the mold during the injection process are presented, and the effects of the sorption term, injection pressure and fibrous medium permeability analyzed.

Abstract: Resin transfer molding (RTM) is one technique that has been used to produce polymer composites, which consists in injecting a thermoset pre-catalysed resin into a closed mold containing a dry fiber preform. In this sense, this study aims to investigate the effect of the calcium carbonate content (CaCO₃) in the polyester resin during the RTM process. Several experiments were conducted using glass fiber mat molded in a RTM system with cavity dimensions 320 x 150 x 3.6 mm, at room temperature, and different injection pressure (0.75 bar) and CaCO₃content (0, 10, 20, 30 and 40%). Results of the physical parameters such as viscosity, permeability, and mobility, and flow front position of the resin into the mold along the RTM process are presented and analyzed. From the results was concluded that the higher the injection pressure and lower CaCO₃content into the resin, the lower filling time.

Abstract: This chapter aims to present a theoretical study of the fluid flow in porous media, with particular reference to manufacturing of polymer composites reinforced with fibers via resin transfer molding process. The mass and momentum conservation equations, including the effect of resin sorption by the fibers, and Darcy's law, are presented, and the analytical solution of the governing equation is obtained via method of separation of variables. Predicted results of the flow front, velocity, volumetric flow rate and pressure fields of the resin inside the model, during the injection process, are presented, and the effects of the injection pressure, resin viscosity and sorption term, are also analyzed.

Abstract: This chapter focuses on the manufacturing of polymer composites reinforced by synthetic fiber with emphasis to the resin transfer molding technique (RTM). Herein, different related topics to foundations, classification, constituents and technological applications of polymer composites are presented. The problems associated to reinforcement and matrix interface and the manufacturing techniques of polymer composites are discussed. The study confirms RTM technique as a highly efficient process as compared with other manufacturing techniques of polymer composites.

Abstract: SMART materials have gained several applications in industries, especially aeronautical and biomedical. Therefore, the fabrication process of these materials must present quality in the completion and dimensioning, in addition to well established mechanical properties. In this sense, the Resin Transfer Molding (RTM) process is presented as an alternative to the manufacture of such products. This process presents advantages compared to other methods, such as, product quality and low cost. Thus, this work aims to model and simulate numerically the manufacturing process of polymer composite reinforced with NiTi shape memory alloy by RTM using the Ansys CFX commercial software. Results of pressure, velocity and volume fractions fields of the phases are presented and discussed. It was verified that the process parameters, like injection pressure and resin inlet and air outlet positions influenced the total time of the process and final product quality.

Abstract: The Resin Transfer Molding process (RTM) has been widely used for manufacturing of high performance components in aerospace and automotive industries. It is an economical and faster method when compared to open molding process because it allows the molding of complex parts with constant thickness, dimensional precision, good surface finishing and an excellent control of mechanical properties. In this sense, this work aims to study theoretically the manufacture process of polymeric composites reinforced with fibers via resin transfer molding. The governing equations of conservation of mass and momentum, and Darcy's law are presented, and the exact solution of the problems is obtained via method of separation of variables. Predicted results of the flow front and the pressure fields of the resin inside the model during the injection process are presented, compared with experimental data and analyzed. It was verified a good agreement between the results.

Abstract: This work aims to investigate the infiltration of a CaCO₃ filled resin in fibrous porous media (resin transfer molding process) using the PAM-RTM software. A preform of glass fiber mat (fraction 30%), with dimensions 320 x 150 x 3.6 mm, has been used in rectilinear injection experiments conducted at room temperature and injection pressure 0.25, 0.50 and 0.75 bar. The polyester resin contain 0% and 40% CaCO₃. The numerical results were evaluated by direct comparison with experimental data. The flat flow-front profile of the rectilinear flow was reached approximately half length of the mold. It was observed, that the both velocity infiltration and permeability have decreased with increasing the CaCO₃ content, thus, increasing the time to processing of the composite material.