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Recently, the liquid composite molding technique (LCM) has been used for producing fiber-reinforced polymer composites, since it allows the molding of complex parts, presenting good surface finishing and control of the mechanical properties of the product at the end of the process. Studies in this area have been focused on resin transfer molding (RTM), specifically on the resin rectilinear infiltration through the porous preform inserted in the closed cavity neglecting the sorption effect of the polymeric fluid by the reinforcement. Thus, the objective of this work is to predict resin radial flow in porous media (fibrous preform), including the effect of resin sorption by fibers considering a one-dimensional approach. For correct prediction of the flow behavior inside the porous media, an advanced modeling approach composed of the mass conservation equation and Darcy's law is used, and the solution of the coupled equation is obtained. Transient results of the flow front location, velocity and pressure within the mold during the resin infiltration are shown, the effects of different parameters for resin (viscosity), reinforcement (sorption term, permeability and porosity) and process (injection pressure and injection radius) are analyzed, and an in-depth discussion is performed. [ABSTRACT FROM AUTHOR]

This study evaluates multimodal imaging for characterizing microstructures in partially impregnated thermoplastic matrix composites made of woven glass fiber and polypropylene. The research quantifies the impregnation degree of fiber bundles within composite plates manufactured through a simplified compression resin transfer molding process. For comparison, a reference plate was produced using compression molding of film stacks. An original surface polishing procedure was introduced to minimize surface defects while polishing partially impregnated samples. Extended-field 2D imaging techniques, including polarized light, fluorescence, and scanning electron microscopies, were used to generate images of the same microstructure at fiber-scale resolutions throughout the plate. Post-processing workflows at the macro-scale involved stitching, rigid registration, and pixel classification of FM and SEM images. Meso-scale workflows focused on 0°-oriented fiber bundles extracted from extended-field images to conduct quantitative analyses of glass fiber and porosity area fractions. A one-way ANOVA analysis confirmed the reliability of the statistical data within the 95% confidence interval. Porosity quantification based on the conducted multimodal approach indicated the sensitivity of the impregnation degree according to the layer distance from the pool of melted polypropylene in the context of simplified-CRTM. The findings underscore the potential of multimodal imaging for quantitative analysis in composite material production. [ABSTRACT FROM AUTHOR]

A co-curing resin system consisting of 9368 epoxy resin for prepreg and 6808 epoxy resin for resin transfer molding (RTM) was developed. A corresponding preparation method for a novel polymer composite bolted T-joint with internal skeleton and external skin was proposed based on the prepreg-RTM co-curing process, and novel T-joints were fabricated. A series of conventional configuration T-joints based on the RTM process and T-joints made of 2A12 aluminum alloy were prepared simultaneously. Bending performances were studied on these T-joints experimentally. The results indicate that 9368 epoxy resin and 6808 epoxy resin exhibit good compatibility in rheological and thermophysical properties. The novel T-joints prepared with the prepreg-RTM co-curing process show no obvious fiber local winding or resin-rich regions inside, and the interface quality between the internal skeleton and the external skin is excellent. The main failure modes of the novel T-joint under bending load include the separation of the skin and skeleton and the fracture along the thickness on the base panel; the skeleton carries the main bending load, but there is still load transfer between external skin and internal skeleton through their interface. The internal damages of the novel T-joint are highly consistent with surface damages observed visually, facilitating the detection and timely discovery of damages. The initial stiffness, damage initiation load, and ultimate load of the novel T-joint are 1.65 times, 5.89 times, and 3.45 times that of the conventional T-joint, respectively. When considering the influence of the density, the relative initial stiffness and relative ultimate load of the novel T-joint are 1.44 times and 2.07 times that of the aluminum alloy T-joint, respectively. [ABSTRACT FROM AUTHOR]

The aim of this work is to analyze the effect of water absorption on the mechanical properties and damage mechanisms of polyester/glass fiber/jute fiber hybrid composites obtained using the compression molding and vacuum-assisted resin transfer molding (VARTM) techniques with different stacking sequences. For this purpose, the mechanical behavior under tensile stress of the samples was evaluated before and after hygrothermal aging at different temperatures: TA, 50 °C, and 70 °C for a period of 696 h. The damage mechanism after the mechanical tests was evaluated using SEM analysis. The results showed a tendency for the mechanical properties of the composites to decrease with exposure to an aqueous ambient, regardless of the molding technique used to conform the composites. It was also observed that the stacking sequence had no significant influence on the dry composites. However, exposure to the aqueous ambient led to a reduction in mechanical properties, both for the molding technique and the stacking sequence. Damage such as delamination, fiber pull-out, fiber/matrix detachment, voids, and matrix removal were observed in the composites in the SEM analyses. [ABSTRACT FROM AUTHOR]

The aim of this work is to analyze water sorption in hybrid polyester/glass fabric/jute fabric composites molded via compression and VARTM (Vacuum-Assisted Resin Transfer Molding). The laminates were produced with five different stacking sequences and subjected to water sorption testing at room temperature, 50 °C and 70 °C. This study consisted of two stages: experimental and theoretical stages. The composites had a fiber volume content ranging from 30% to 40%. Water absorption and diffusion coefficient in the hybrid composites were intermediate to those reinforced with a single type of fiber. There were no significant differences in these properties based on fiber arrangement once the composites reached saturation. Diffusion coefficient values were higher for specimens with jute fiber on at least one of the outer surfaces. Water sorption rates increased with higher immersion temperatures. The water sorption at saturation point was not affected by the manufacturing process. Among the hybrid composites, those with jute on the surfaces showed the highest diffusion coefficient, while those with glass on the surface had the lowest values. Higher diffusion coefficient values were observed at temperatures of 50 °C and 70 °C. The main influencing factors on the absorbed moisture content for composites are the presence and content of jute fibers in the system and the immersion temperature. The manufacturing process does not affect the water sorption at saturation point. [ABSTRACT FROM AUTHOR]

Thermoplastic resin transfer molding (T-RTM) technology was applied to synthesize graphene nanoplatelets-based nanocomposites via anionic ring-opening polymerization (AROP). Polyamide 6 (PA6) was obtained by AROP and was used as the polymeric matrix of the developed nanocomposites. The non-isothermal crystallization behavior of PA6 and nanocomposites was analyzed by differential scanning calorimetry (DSC). Nanocomposites with 0.5 wt.% of graphene nanoplatelets (GNPs) with two different diameter sizes were prepared. Results have shown that the crystallization temperature shifted to higher values in the presence of GNPs. This behavior is more noticeable for the nanocomposite prepared with smaller GNPs (PA6/GN). The crystallization kinetic behavior of all samples was assessed by Avrami and Liu's models. It was observed that GNPs increased the crystallization rate, thus revealing a nucleating ability, and also validated the reduction of half-time crystallization values. Such tendency was also supported by the lower activation energy values determined by Friedman's method. [ABSTRACT FROM AUTHOR]

Standard lay-up fabrication of fiber-reinforced composites (FRCs) suffer from poor out-of-plane properties and delamination resistance. While advanced manufacturing techniques (e.g., interleaving, braiding, and z-pinning) increase delamination resistance in FRCs, they typically result in significant fabrication complexity and limitations, increased manufacturing costs, and/or overall stiffness reduction. In this work, we demonstrate the use of facile digital light processing (DLP) technique to additively manufacture (AM) random glass FRCs with engineered interleaves. This work demonstrates how vat photo-polymerization techniques can be used to build composites layer-by-layer with controlled interleaf material, thickness, and placement. Note that this engineering control is almost impossible to achieve with traditional manufacturing techniques. A range of specimens were printed to measure the effect of interleaf thickness and material on tensile/flexural properties as well as fracture toughness. One important observation was the ≈60% increase in interlaminar fracture toughness achieved by using a tough resin material in the interleaf. The comparison between AM and traditionally manufactured specimens via vacuum-assisted resin transfer molding (VARTM) highlighted the limitation of AM techniques in achieving high mat consolidation. In other words, the volume fraction of AM parts is limited by the wet fiber mat process, and engineering solutions are discussed. Overall, this technique offers engineering control of FRC design and fabrication that is not available with traditional methods. [ABSTRACT FROM AUTHOR]

Recently, fiber-reinforced, epoxy-based, optically transparent composites were successfully produced using resin transfer molding (RTM) techniques. Generally, the production of structural, optically transparent composites is challenging since it requires the combination of a very smooth mold surface with a sufficient control of resin flow that leads to no visible voids. Furthermore, it requires a minimum deviation of the refractive indices (RIs) of the matrix polymer and the reinforcement fibers. Here, a new mold design is described and three plates of optically transparent glass fiber-reinforced polymers (tGFRP) with reproducible properties as well as high fiber volume fractions were produced using the RTM process and in situ polymerization of an epoxy resin system enclosing E-glass fiber textiles. Their mechanical (flexural), microstructural (fiber volume fraction, surface roughness, etc.), thermal (DSC, TGA, etc.), and optical (dispersion curves of glass fibers and polymer as well as transmission over visible spectra curves of the tGFRP at varying tempering states) properties were evaluated. The research showed improved surface quality and good transmission data for samples manufactured by a new Optical-RTM setup compared to a standard RTM mold. The maximum transmission was reported to be ≈74%. In addition, no detectable voids were found in these samples. Furthermore, a flexural modulus of 23.49 ± 0.64 GPa was achieved for the Optical-RTM samples having a fiber volume fraction of ≈42%. [ABSTRACT FROM AUTHOR]

This paper studies the ballistic impact performance of 3D woven composites (3DWCs) with hexagonal binding patterns. Para-aramid/polyurethane (PU) 3DWCs with three kinds of fiber volume fraction (Vf) were prepared by compression resin transfer molding (CRTM). The effect of Vf on the ballistic impact behavior of the 3DWCs was analyzed by characterizing the ballistic limit velocity (V50), the specific energy absorption (SEA), the energy absorption per thickness (Eh), the damage morphology and the damage area. 1.1 g fragment-simulating projectiles (FSPs) were used in the V50 tests. Based on the results, when the Vf increases from 63.4% to 76.2%, the V50, the SEA and the Eh increase by 3.5%, 18.5% and 28.8%, respectively. There are significant differences in damage morphology and damage area between partial penetration (PP) cases and complete penetration (CP) cases. In the PP cases, the back-face resin damage areas of the sample III composites were significantly increased to 213.4% of the sample I counterparts. The findings provide valuable information for the design of ballistic protection 3DWCs. [ABSTRACT FROM AUTHOR]

A composite thin shell with a high fiber volume fraction prepared by resin transfer molding (RTM) may have void defects, which create deformations in the final curing and lead to the final product being unable to meet the actual assembly requirements. Taking a helmet shell as an example, a multi-directional compression RTM (M-CRTM) method with an adjustable injection gap is proposed according to the shape of the thin shell. This method can increase the injection gap to reduce the fiber volume fraction during the injection process, making it easier for the resin to penetrate the reinforcement and for air bubbles to exit the mold. X-ray CT detection shows that the porosity of the helmet shell prepared by the newly developed technology is 36.6% lower than that of the RTM-molded sample. The void's distribution is more uniform, and its size is decreased, as is the number of voids, especially large voids. The results show that the maximum curing deformation of the M-CRTM-molded helmet shell is reduced by 13.7% compared to the RTM molded sample. This paper then further studies the deformation types of the shell and analyzes the causes of such results, which plays an important role in promoting the application of composite thin shells. [ABSTRACT FROM AUTHOR]

Tailored fiber placement (TFP) is a preform manufacturing process in which rovings made of fibrous material are stitched onto a base material, increasing the freedom for the placement of fibers. Due to the particular kinematics of the process, the infiltration of TFP preforms with resin transfer molding (RTM) is sensitive to multiple processes and material parameters, such as injection pressure, resin viscosity, and fiber architecture. An experimental study is conducted to investigate the influence of TFP manufacturing parameters on the infiltration process. A transparent RTM tool that enables visual tracking of the resin flow front was developed and constructed. Microsection evaluations were produced to observe the thickness of each part of the composite and evaluate the fiber volume content of that part. Qualitative results have shown that the infiltration process in TFP structures is strongly influenced by a top and bottom flow layer. The stitching points and the yarn also create channels for the resin to flow. Furthermore, the stitching creates some eye-like regions, which are resin-rich zones and are normally not taken into account during the infusion of TFP parts. [ABSTRACT FROM AUTHOR]

The aim of this study was to specifically explore the effects of morpholine on chemical surface treatments of aged resin composites contaminated with saliva to new resin composite repair strength. One hundred and thirty five resin composite specimens were fabricated and thermocycled to replicate an aged resin composite. These aged resin composites were randomly separated into nine groups (n = 15) depending on the various surface contaminants and surface treatment techniques. These groups were as follows: group 1—no surface treatment; group 2—no saliva + adhesive agent; group 3—no saliva + morpholine + adhesive agent; group 4—no saliva + morpholine; group 5—saliva; group 6—saliva + adhesive agent; group 7—saliva + morpholine + adhesive agent; group 8—saliva + morpholine; and group 9—saliva + phosphoric acid + adhesive agent. A mold was covered on the top of the specimen center and then filled with resin composite. The shear bond strengths and failure modes were examined. The collected data was analyzed using one-way ANOVA, and the significance level was determined using Tukey's test. Group 5 (3.31 ± 0.95 MPa) and group 6 (4.05 ± 0.93 MPa) showed the lowest bond strength statistically, while group 3 (23.66 ± 1.35 MPa) and group 7 (22.88 ± 1.96 MPa) showed the most significantly high bond strength. The bond strength in group 2 (16.41 ± 1.22 MPa) was significantly different from that in group 1 (9.83 ± 1.13 MPa), group 4 (10.71 ± 0.81 MPa), and group 8 (10.36 ± 1.53 MPa), while group 9's (17.31 ± 1.48 MPa) SBS was not significantly different. In conclusion, the application of morpholine on aged resin composite with or without contamination with saliva prior to the application of the adhesive agent increased the bond strength of aged resin composite repaired with new resin composite (p < 0.05). [ABSTRACT FROM AUTHOR]

Reactive thermoplastics matrices offer ease of processing using well-known molding techniques (such as Resin Transfer Molding) due to their initially low viscosity. For Polyamide 6 (PA6)/glass composites, the hydroxyl groups on the glass surface slow down the anionic ring-opening polymerization (AROP) reaction, and can ultimately inhibit it. This work aims to thoroughly control the hydroxyl groups and the surface chemistry of glass particulates to facilitate in situ AROP-an aspect that has been barely explored until now. A model system composed of a PA6 matrix synthesized by AROP is reinforced with calcinated and silanized glass microparticles. We systematically quantify, by TGA and FTIR, the complete particle surface modification sequence, from the dehydration, dehydroxylation and rehydroxylation processes, to the silanization step. Finally, the impact of the particle surface chemistry on the polymerization and crystallization of the PA6/glass composites was quantified by DSC. The results confirm that a careful balance is required between the dehydroxylation process, the simultaneous rehydroxylation and silane grafting, and the residual hydroxyl groups, in order to maintain fast polymerization and crystallization kinetics and to prevent reaction inhibition. Specifically, a hydroxyl concentration above 0.2 mmol OH·g−1 leads to a slowdown of the PA6 polymerization reaction. This reaction can be completely inhibited when the hydroxyl concentration reaches 0.77 mmol OH·g−1 as in the case of fully rehydroxylated particles or pristine raw particles. Furthermore, both the rehydroxylation and silanization processes can be realized simultaneously without any negative impact on the polymerization. This can be achieved with a silanization time of 2 h under the treatment conditions of the study. In this case, the silane agent gradually replaces the regenerated hydroxyls. This work provides a roadmap for the preparation of reinforced reactive thermoplastic materials. [ABSTRACT FROM AUTHOR]

A method for the synthesis of an amine-containing epoxy resin curing agent by dissolving hexakis-[(4-formyl)phenoxy]cyclotriphosphazene in an excess of isophoronediamine was developed. The curing agent was characterized via NMR and IR spectroscopy and MALDI-TOF mass spectrometry, and its rheological characteristics were studied. Compositions based on DER-354 epoxy resin and the synthesized curing agent with different amounts of phosphazene content were obtained. The rheological characteristics of these compositions were studied, followed by their curing. An improvement in several thermal (DSC), mechanical (compression, tension, and adhesion), and physicochemical (water absorption and water solubility) characteristics, as well as the fire resistance of the obtained materials modified with phosphazene, was observed, compared with unmodified samples. In particular, there was an improvement in adhesive characteristics and fire resistance. Thus, compositions based on a curing agent containing a 30% modifier were shown to fulfill the V-1 fire resistance category. The developed compositions can be processed by contact molding, winding, and resin transfer molding (RTM), and the resulting material is suitable for use in aircraft, automotive products, design applications, and home repairs. [ABSTRACT FROM AUTHOR]

To meet the expectation of the industry, resin transfer molding (RTM) has become one of the most promising polymer processing methods to manufacture fiber-reinforced plastics (FRPs) with light weight, high strength, and multifunctional features. The permeability and porosity of fiber reinforcements are two of the primary properties that control the flow of resin in fibers and are critical to numerical simulations of RTM. In the past, various permeability measurement methods have been developed in the literature. However, limitations still exist. Furthermore, porosity is often measured independently of permeability. As a result, the two measurements do not necessarily relate to the same entity, which may increase the time and labor costs associated with experiments and affect result interpretation. In this work, a measurement system was developed by fusing the signals from capacitive sensing and flow visualization, based on which a novel algorithm was developed. Without complicated sensor design or expensive instrumentation, both in-plane permeability and porosity can be simultaneously estimated. The feasibility of the proposed method was illustrated by experiments and verified with numerical simulations. [ABSTRACT FROM AUTHOR]

Benefiting from the multi-directional load-bearing capability, the three-dimensional braided composites (3DBC) have found a wide application in primary structures. It is therefore of great importance to fully understand their mechanical behavior and failure modes. In the present paper, the tensile and compressive tests were carried out, according to standardized testing methods, for eight types of 3DBC, which were manufactured by resin transfer molding (RTM). It was found that the mechanical properties of the 3DBCs decreased with an increasing braiding angle. When the braiding angle was 20°, 3D 5-directional braided composite (3D5dBC) exhibited the best mechanical properties, while for the braiding angle of 40°, the mechanical properties of 3D6dBC were the most prominent. Moreover, the tensile strength of the 3DBCs is approximately two times as much as the compressive strength; however, the compressive modulus is always 10% higher than the tensile modulus. The failure modes of the 3DBCs with a braiding angle of 20°greatly depended on the braiding structures. However, they tend to be consistent when the braiding angle increases to 40°. [ABSTRACT FROM AUTHOR]

The current drive for sustainability demands recyclable matrices for composite materials. Vitrimers combine thermoset properties with reprocessability, but their mechanical performance in highly loaded applications, for instance, composites for aeronautics, is still to be demonstrated. This work presents the complete mechanical characterization of a new vitrimer reinforced with carbon fiber. This vitrimer formulation consists of functional epoxy groups and a new dynamic disulfide crosslinks-based hardener. The testing campaign for the vitrimer composites encompassed tension, compression, interlaminar shear strength (ILSS), in-plane shear (IPS), open-hole tension (OHT) and compression (OHC), filled-hole compression (FHC) and interlaminar fracture toughness tests under mode I and II. Test conditions included room temperature and high temperature of 70 °C and 120 °C, respectively, after moisture saturation. Tension and flexural tests also were applied on the neat vitrimer resin. The results compared well with those obtained for current aeronautic materials manufactured by Resin Transfer Molding (RTM). The lower values observed in compression and ILSS derived from the thermoplastic veils included as a toughening material. This work demonstrates that the vitrimer formulation presented meets the requirements of current matrices for aeronautic-grade carbon-reinforced composites. [ABSTRACT FROM AUTHOR]

Resin transfer moulding (RTM) is commonly used for the production of high-performance fibre-reinforced polymer composites. In numerous application areas, the addition of fillers is necessary to enhance some properties of the polymer matrix or provide it with additional properties, such as flame retardancy. As many of the applied additives are solid phase, the reinforcement layers may filter the solid phase additive particles during RTM, resulting in a non-uniform distribution and uneven performance. Consequently, the proper distribution of the solid phase additives in composites is of key importance. This review primarily aims at facilitating the production of flame retarded structural composites by RTM in cases where the required fire performance can only be achieved with solid additives. First, the parameters influencing the particle distribution, along with the models describing it, are reviewed. Then, analytical methods for determining the particle distribution in composites manufactured by RTM are presented. Finally, the possible solutions to improve the particle distribution of solid phase additives are outlined. [ABSTRACT FROM AUTHOR]

In this work a holistic approach for the characterization and mathematical modeling of the reaction kinetics of a fast epoxy resin is shown. Major composite manufacturing processes like resin transfer molding involve isothermal curing at temperatures far below the ultimate glass transition temperature. Hence, premature vitrification occurs during curing and consequently has to be taken into account by the kinetic model. In order to show the benefit of using a complex kinetic model, the Kamal-Malkin kinetic model is compared to the Grindling kinetic model in terms of prediction quality for isothermal processing. From the selected models, only the Grindling kinetic is capable of taking into account vitrification. Non-isothermal, isothermal and combined differential scanning calorimetry (DSC) measurements are conducted and processed for subsequent use for model parametrization. In order to demonstrate which DSC measurements are vital for proper cure modeling, both models are fitted to varying sets of measurements. Special attention is given to the evaluation of isothermal DSC measurements which are subject to deviations arising from unrecorded cross-linking prior to the beginning of the measurement as well as from physical aging effects. It is found that isothermal measurements are vital for accurate modeling of isothermal cure and cannot be neglected. Accurate cure predictions are achieved using the Grindling kinetic model. [ABSTRACT FROM AUTHOR]

Resin transfer molding (RTM) is a popular manufacturing technique that produces fiber reinforced polymer (FRP) composites. In this paper, a model-assisted flow front control system is developed based on real-time estimation of permeability/porosity ratio using the information acquired by a visualization system. In the proposed control system, a radial basis function (RBF) network meta-model is utilized to predict the position of the future flow front by inputting the injection pressure, the current position of flow front, and the estimated ratio. By conducting optimization based on the meta-model, the value of injection pressure to be implemented at each step is obtained. Moreover, a cascade control structure is established to further improve the control performance. Experiments show that the developed system successfully enhances the performance of flow front control in RTM. Especially, the cascade structure makes the control system robust to model mismatch. [ABSTRACT FROM AUTHOR]

The bladder molding process is primarily used in sporting applications but mostly with prepregs. Bladder-Assisted Resin Transfer Molding (B-RTM) presents the tremendous potential to automate and mass produce the complex hollow-composite profiles. Thin-ply, non-crimp fabrics (NCFs) provide excellent mechanical, fracture toughness, and vibration damping properties on top of the weight saving it offers to a final product. However, these fiber architectures are difficult to inject due to the resistance they provide for the polymer flow using the liquid injection process. Therefore, it is mandatory to optimize the process parameters to reduce the time for injection and simultaneously achieve better consolidation. This work presents a first, detailed, experimental case study to successfully inject a low-permeability, thin-ply, complex, thermoplastic tubular structure, and the effect of process parameters, boundary conditions, the associated manufacturing challenges, and proposed solutions are deliberated in this paper. [ABSTRACT FROM AUTHOR]

In this work, laminated polyester thermoset composites based on palm tree fibers extracted from palms leaflets and glass mats fibers were manufactured to develop hybrid compositions with good mechanical properties; the mixture of fibers was elaborated to not exceed 25 vol.%. Samples were prepared with a resin transfer molding (RTM) method and mechanically characterized using tensile and flexural, hardness, and impact tests, and ultrasonic waves as a non-destructive technique. The water sorption of these composite materials was carried out in addition to solar irradiation aging for approximately 300 days to predict the applicability and the long-term performance of the manufactured composites. Results have shown that the use of glass fibers significantly increased all properties; however, an optimum combination of the mixture could be interesting and could be developed with less glass sheet and more natural fibers, which is the goal of this study. On the other hand, exposure to natural sunlight deteriorated the mechanical resistance of the neat resin after only 60 days, while the composites kept high mechanical resistance for 365 days of exposure. [ABSTRACT FROM AUTHOR]

Near-infrared spectroscopy (NIR) was implemented in the resin transfer molding (RTM) process to inline monitor the degree of curing of a bio-based epoxy resin, which consists of epoxidized linseed oil (resin) and citric acid (hardener), respectively. A NIR micro-spectrometer was used for the development of robust calibration models using partial least squares (PLS) regression. Since the micro-spectrometer offers a smaller wavelength range compared with conventional NIR devices, and typical absorbance peaks are not directly involved in the captured data range, the results show new insights for the utilization of this technology. Different pre-treatments of the spectroscopic data have been tested, starting with different reference spectra, i.e., uncured resin and polytetrafluorethylene (PTFE), and followed by chemometrical algorithms. As a reference method for the degree of curing, direct current (DC) supported by differential scanning calorimetry (DSC) was used. The results show the potential of these cost-efficient and compact NIR micro-spectrometers for the intended inline monitoring purpose to gain relevant information feedback during the process. [ABSTRACT FROM AUTHOR]

Strengthening steel structures by using carbon fiber reinforced polymer (CFRP) laminates showed a growth trend in the last several years. A similar strengthening technique, known as adhesive bonding, has also been adopted. This paper presented a promising alternative for strengthening steel members against buckling by using vacuum-assisted resin transfer molding (VaRTM)-processed unbonded CFRP laminates. A total of thirteen slender angle steel members (L65x6), including two control specimens, were prepared and experimentally tested. The specimens were strengthened only at both legs and were allowed to buckle on their weak axes. The test showed that the unbonded CFRP strengthening successfully increased the buckling capacity of the angle steel. The strengthening effect ranged from 7.12% to 69.13%, depending on various parameters (i.e., number of CFRP layers, CFRP length, and angle steel's slenderness ratio). Flexural stiffness of the CFRP governed the failure modes in terms of location of plastic hinge and direction of buckling curvature. [ABSTRACT FROM AUTHOR]

To avoid the delamination of the traditional three-dimensional (3-D) honeycomb electromagnetic (EM) absorbing composites and improving the defects of low mechanical properties, the 3-D honeycomb woven fabrics were woven on the ordinary loom by practical design. The fabrication of 3-D honeycomb woven EM absorbing composites was based on carbon black/carbonyl iron powder/basalt fiber/carbon fiber/epoxy resin (CB/CIP/BF/CF/EP) by the vacuum-assisted resin transfer molding (VARTM) process. A CB/CIP composite absorbent study showed that CB/CIP composite absorbent belongs to a magnetic loss type absorbent. Adding CB/CIP significantly improved the absorption performance of composite, increased the absorption peak and the effective absorption bandwidth (EAB), but the bending performance decreased. The normalization analysis results showed that when the thickness was 15 mm, the mechanical properties and EM wave-absorbing properties of the 3-D honeycomb woven composite were the best matches. The morphological characteristics and displacement load curves of the composite after fracture were analyzed. The bending failure modes were brittle fracture of the fiber bundle, matrix cracking, and typical shear failure. Despite the above failure mechanism, the 3-D honeycomb woven EM absorbing composites still has good integrity without delamination. [ABSTRACT FROM AUTHOR]

The purpose of this study was to manufacture hybrid composites from fabrics with superior ballistic performance, and to analyze their viscoelastic and mechanical response. Therefore, composites in hybrid lay-up modes were manufactured from Vectran, Kevlar and aluminum fiber-woven fabrics through a vacuum assisted resin transfer molding. The specimens were consequently analyzed using static three-point bending, as well as by dynamic mechanical analysis (DMA). Apart from DMA, time–temperature superposition (TTS) analysis was performed by all available models. It was possible to study the intrinsic viscoelastic behavior of hybrid ballistic laminates, with TTS analysis gained from creep testing. A polynomic mathematical function was proposed to provide a high accuracy for TTS curves, when shifting out of the linearity regimes is required. The usual Williams–Landel–Ferry and Arrhenius models proved not useful in order to describe and model the shift factors of the acquired curves. In terms of static results, the highly nonlinear stress–strain curve of both composites was obvious, whereas the differential mechanism of failure in relation to stress absorption, at each stage of deformation, was studied. SEM fractography revealed that hybrid specimens with Kevlar plies are prone to tensile side failure, whereas the hybrid specimens with Vectran plies exhibited high performance on the tensile side of the specimens in three-point bending, leading to compressive failure owing to the high stress retained at higher strains after the maximum bending strength was reached. [ABSTRACT FROM AUTHOR]

It has been known in the industrial sector that in closely intermeshing counterrotating twin screw extruders, large separating forces develop in the calender gap, which push the screws towards the barrel wall. The result is significant wear in the region defined by 30°- and 60°-degree angles from the vertical. In the present investigation, pressures were measured around the barrel in extrusion of two rigid PVC resins in a laboratory extruder of 55 mm diameter and the forces on the screw core were determined. Numerical flow simulations were also carried out using the power-law viscosity parameters of the resins. From the experimental results, it was determined that the resultant forces are in the 30 degree angle direction, and from the computer simulations, the angle is between 18° and 25°. It is argued that the resultant force angle will be somewhat larger in large diameter extruders, due to the additional contribution of gravity. [ABSTRACT FROM AUTHOR]

Fiber-reinforced composite structures are used in different applications due to their excellent strength to weight ratio. Due to cost and tool handling issues in conventional manufacturing processes, like resin transfer molding (RTM) and autoclave, vacuum-assisted resin transfer molding (VARTM) is the best choice among industries. VARTM is highly productive and cheap. However, the VARTM process produces complex, lightweight, and bulky structures, suitable for mass and cost-effective production, but the presence of voids and fiber misalignment in the final processed composite influences its strength. Voids are the primary defects, and they cannot be eliminated completely, so a design without considering void defects will entail unreliability. Many conventional failure theories were used for composite design but did not consider the effect of voids defects, thus creating misleading failure characteristics. Due to voids, stress and strain uncertainty affects failure mechanisms, such as microcrack, delamination, and fracture. That's why a proper selection and understanding of failure theories is necessary. This review discusses previous conventional failure theories followed by work considering the void's effect. Based on the review, a few prominent theories were suggested to estimate composite strength in the void scenario because they consider the effect of the voids through crack density, crack, or void modeling. These suggested theories were based on damage mechanics (discrete damage mechanics), fracture mechanics (virtual crack closure technique), and micromechanics (representative volume element). The suggested theories are well-established in finite element modeling (FEM), representing an effective time and money-saving tool in design strategy, with better early estimation to enhance current design practices' effectiveness for composites. This paper gives an insight into choosing the failure theories for composites in the presence of voids, which are present in higher percentages in mass production and less-costly processes (VARTM). [ABSTRACT FROM AUTHOR]

Phenylethynyl-terminated aromatic polyimides meet requirements of resin transfer molding (RTM) and exhibits high glass transition temperature (Tg) were prepared. Moreover, the relationship between the polyimide backbones structure and their melting stability was investigated. The phenylethynyl-terminated polyimides were based on 4,4′-(hexafluorosiopropylidene)-diphthalic anhydride (6FDA) and different diamines of 3,4′-oxydianiline (3,4′-ODA), m-phenylenediamine (m-PDA) and 2,2′-bis(trifluoromethyl)benzidine (TFDB) were prepared. These oligoimides exhibit excellent melting flowability with wide processing temperature window and low minimum melt viscosities (<1 Pa·s). Two of the oligoimides display good melting stability at 280–290 °C, which meet the requirements of resin transfer molding (RTM) process. After thermally cured, all resins show high glass transition temperatures (Tgs, 363–391 °C) and good tensile strength (51–66 MPa). The cure kinetics studied by the differential scanning calorimetry (DSC), 13C nuclear magnetic resonance (13C NMR) characterization and density functional theory (DFT) definitely confirmed that the electron-withdrawing ability of oligoimide backbone can tremendously affect the curing reactivity of terminated phenylethynyl groups. The replacement of 3,4′-ODA units by m-PDA or TFDB units increase the electron-withdrawing ability of the backbone, which increase the curing rate of terminated phenylethynyl groups at processing temperatures, hence results in the worse melting stability. [ABSTRACT FROM AUTHOR]

This contribution focuses on the development of flax and flax/basalt hybrid reinforced composites based on epoxidized linseed oil (ELO) resin, exploiting the feasibility of different ratios of glutaric anhydride (GA) to maleinized linseed oil (MLO) in the hardener system (50:0, 40:10 and 30:20 wt.%) to provide crosslinked thermosets with balanced properties. The hybrid laminates have been manufactured by resin transfer molding (RTM) and subjected to dynamic–mechanical (DMA) and thermal gravimetry (TGA) analysis. The presence of glutaric anhydride (GA) resulted in hard and relatively brittle flax and flax/basalt laminates, whose loss moduli decreased as the number of basalt plies diminished. Furthermore, the increase in MLO content in the GA:MLO hardener system shifted the glass transition temperatures (Tg) from 70 °C to 59 and 56 °C, which is representative of a decrease in brittleness of the crosslinked resin. All samples exhibited two stages of their decomposition process irrespective of the MLO content. The latter influenced the residual mass content that increased with the increase of the MLO wt.% from 10 to 30 wt.%, with shifts of the final degradation temperatures from 410 °C to 425 °C and 445 °C, respectively. [ABSTRACT FROM AUTHOR]

We report the fatigue behavior of a novel multiscale fiberglass/epoxy composite modified with reduced-graphene oxide (rGO) and graphene nanoplatelets (GNP). A novel and cost-effective fabrication method based on vacuum assisted resin transfer molding (VARTM) method was used for manufacturing the composite laminates. Morphological and mechanical analysis of composites showed a successful dispersion of nano-fillers and a remarkable improvement in fatigue life of the nanocomposites. The experimental results revealed that all rGO concentrations resulted in a significant increase in fatigue life of the nanocomposites. These enhancements can be explained by the creation of stronger links between the nanoparticles fiberglass and epoxy. The experimental results also showed that lower concentrations of GNPs lead to an increase in fatigue life of nanocomposites; however, a decrease in their fatigue life can be seen at higher loadings. [ABSTRACT FROM AUTHOR]

This work reports the preparation of carbon fiber reinforced thermoplastic composites via the in situ anionic ring opening polymerization of ε-caprolactam. Vacuum assisted resin transfer molding was used to fabricate polyamide-6/carbon fiber composites at different molding temperatures. As a result, the higher polymerization of ε-caprolactam was observed with the condition at 140 °C for satisfactory impregnation. Regarding molding temperature, the physical properties of polyamide-6/carbon fiber were observed that the bending and impact strengths at 140 °C were higher than those to at other molding temperatures. The polymerization kinetics of polyamide-6 was analyzed using differential scanning calorimetry by experimentally acquiring kinetic parameters according to model fitting approaches. Polymerization and crystallization, which occur simultaneously throughout the whole process, were separated using Gaussian and Maxwell–Boltzmann distributions to study polymerization kinetics. The result of the developed model was in good agreement with the experimental data for the presented first order autocatalytic reaction model. [ABSTRACT FROM AUTHOR]

Thermoplastic resin transfer molding (T-RTM) is a cutting-edge manufacturing technique for high-volume production of composites with a recyclable thermoplastic matrix. Although a number of reactive thermoplastic matrices as well as industrial manufacturing equipment for T-RTM are commercially available today, the design of a T-RTM mold is still based on the skills and personal experience of the designer. This study summarizes the best knowledge and expertise in mold design and manufacturing and introduces an innovative mold for T-RTM. A concept and basic principles for designing a T-RTM mold are formulated in this study. The mold developed is manufactured and validated. [ABSTRACT FROM AUTHOR]

Bamboo fibers (BFs)-reinforced epoxy resin (EP) composites are prepared by resin transfer molding (RTM). The influence of BFs surface modification (NaOH solution or coupling agents, i.e., KH550 and KH560) on interfacial properties of BFs/EP composites is systematically investigated. The synergistic effect of hydrolysis, peeling reaction of BFs, and the condensation reaction of hydrolyzed coupling agents are confirmed by FTIR. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) reveal that the interfacial compatibility of NaOH- and silane-modified BFs/EP composites was significantly improved. KH550-modified BFs/EP composite renders optimal tensile, flexural, and impact strength values of 68 MPa, 86 MPa, and 226 J/m. The impact resistance mechanism at the interface of BFs/EP composites was proposed. Moreover, the dynamic mechanical properties, creep behavior, and differential scanning calorimetry of BFs/EP composites have also been carried out to understand thermal stabilities. Overall, the surface-modified BFs-reinforced EP composites exhibited superior interfacial bonding. [ABSTRACT FROM AUTHOR]

In this paper, recent shell model is advanced towards the calibration and validation of the Vacuum-assisted Resin Transfer Molding (VARTM) process in a novel way. The model solves the nonlinear and strongly coupled resin flow and preform deformation when the 3-D flow and stress problem is simplified to a corresponding 2-D problem. In this way, the computational efficiency is enhanced dramatically, which allows for simulations of the VARTM process of large scale thin-walled structures. The main novelty is that the assumptions of the neglected through-thickness flow and the restricted preform deformation along the normal of preform surface suffice well for the thin-walled VARTM process. The model shows excellent agreement with the VARTM process experiment. With good accuracy and high computational efficiency, the shell model provides an insight into the simulation-based optimization of the VARTM process. It can be applied to either determine locations of the gate and vents or optimize process parameters to reduce the deformation. [ABSTRACT FROM AUTHOR]

Thermoplastic resin transfer molding (T-RTM) is attracting much attention due to the need for recyclable alternatives to thermoset materials. In this work, we have prepared polyamide-6 (PA6) and PA6/fiber composites by T-RTM of caprolactam. Glass and carbon fibers were employed in a fixed amount of 60 and 47 wt.%, respectively. Neat PA6 and PA6 matrices (of PA6-GF and PA6-CF) of approximately 200 kg/mol were obtained with conversion ratios exceeding 95%. Both carbon fibers (CF) and glass fibers (GF) were able to nucleate PA6, with efficiencies of 44% and 26%, respectively. The α crystal polymorph of PA6 was present in all samples. The lamellar spacing, lamellar thickness and crystallinity degree did not show significant variations in the samples with or without fibers as result of the slow cooling process applied during T-RTM. The overall isothermal crystallization rate decreased in the order: PA6-CF > PA6-GF > neat PA6, as a consequence of the different nucleation efficiencies. The overall crystallization kinetics data were successfully described by the Avrami equation. The lamellar stack morphology observed by atomic force microscopy (AFM) is consistent with 2D superstructural aggregates (n = 2) for all samples. Finally, the reinforcement effect of fibers was larger than one order of magnitude in the values of elastic modulus and tensile strength. [ABSTRACT FROM AUTHOR]

The production and consumption of polymer composites has grown continuously through recent decades and has topped 10 Mt/year. Until very recently, polymer composites almost exclusively had non-recyclable thermoset matrices. The growing amount of plastic, however, inevitably raises the issue of recycling and reuse. Therefore, recyclability has become of paramount importance in the composites industry. As a result, thermoplastics are coming to the forefront. Despite all their advantages, thermoplastics are difficult to use as the matrix of high-performance composites because their high viscosity complicates the impregnation process. A solution could be reactive thermoplastics, such as PA-6, which is synthesized from the ε-caprolactam (ε-CL) monomer via anionic ring opening polymerization (AROP). One of the fastest techniques to process PA-6 into advanced composites is thermoplastic resin transfer molding (T-RTM). Although nowadays T-RTM is close to commercial application, its optimization and control need further research and development, mainly assisted by modeling. This review summarizes recent progress in the modeling of the different aspects of the AROP of ε-CL. It covers the mathematical modeling of reaction kinetics, pressure-volume-temperature behavior, as well as simulation tools and approaches. Based on the research results so far, this review presents the current trends and could even plot the course for future research. [ABSTRACT FROM AUTHOR]

This study reports the first example of the production of polylactide composites prepared by Thermoplastic Resin Transfer Molding (T-RTM) via in situ bulk polymerization of l-lactide (l-LA) after injection in a closed mold containing glass fabrics. Tin octoate Sn(Oct)2 was used as the catalyst and first evaluated at the lab-scale in the experimental conditions required in the tank and in the mold of the RTM device. The reactions were then upscaled in the RTM in the absence of reinforcement to ensure the feasibility of the process (transfer and polymerization). Finally, poly-l-lactide (PLLA)-based composites with glass fabrics as the reinforcement were obtained. The resulting PLLA matrices exhibited conversions up to 99% along with high molar masses of up to 78,000 g·mol−1 when the polymerization was carried out under dynamic vacuum (vacuum-assisted RTM, VARTM). Moreover, a good impregnation of the glass fabrics by the matrix was observed by optical microscopy. [ABSTRACT FROM AUTHOR]

In liquid composite molding processes, such as resin transfer molding (RTM) and vacuum assisted resin transfer molding (VARTM), the resin is drawn through fiber preforms in a closed mold by an induced pressure gradient. Unlike the RTM, where a rigid mold is employed, in VARTM, a flexible bag is commonly used as the upper-half mold. In this case, fabric deformation can take place during the impregnation process as the resin pressure inside the preform changes, resulting in continuous variations of reinforcement thickness, porosity, and permeability. The proper approach to simulate the resin flow, therefore, requires coupling deformation and pressure field making the process modeling more complex and computationally demanding. The present work proposes an efficient methodology to add the effects of the preform compaction on the resin flow when a deformable porous media is considered. The developed methodology was also applied in the case of Seeman's Composite Resin Infusion Molding Process (SCRIMP). Numerical outcomes highlighted that preform compaction significantly affects the resin flow and the filling time. In particular, the more compliant the preform, the more time is required to complete the impregnation. On the other hand, in the case of SCRIMP, the results pointed out that the resin flow is mainly ruled by the high permeability network. [ABSTRACT FROM AUTHOR]