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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 investigated the manufacturing processes for structural supercapacitors (SSCs) using smear molding (RS), resin transfer molding (RTM), and vacuum-assisted resin transfer molding (VARTM). Woven carbon fibers were used as the electrode, woven glass fibers as an insulating layer, and an alkaline/epoxy compound as the electrolyte. In the RTM process, due to the vacuum and the high-pressure injection of the electrolyte, the electrochemical and mechanical properties of the SSC can be greatly improved, and the void contents in the SSC can be reduced. The balanced electrochemical performance and mechanical properties of SSCs were observed in the range of epoxy content from 15 wt% to 30 wt%. This study contributes to the development of SSCs through the establishment of the fabrication process for improvements in part quality. The fabrication method demonstrated here can be directly applied by industries to produce even larger-scale SSCs, opening up new possibilities for practical implementation and scalability. [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]

Natural fiber composites have been extensively studied for structural applications, with recent exploration into their potential for various uses. This study investigates the impact of chemical treatments on the properties of Brazilian jute woven fabric/polyester resin composites. Sodium hydroxide, hydrogen peroxide, and peracetic acid were utilized to treat the jute fabrics, followed by resin transfer molding (RTM) to form the composites. Evaluation included water absorption, flexural strength, tensile strength, and short-beam strength. The alkaline treatment induced changes in the chemical composition of the fibers' surface. Chemical treatments resulted in increased flexural and short-beam strength of the composites, with no significant alterations in tensile properties. The hydrogen peroxide treatment exhibited lower water absorption, suggesting its potential as a viable option for enhancing the performance of these composites. [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 usage of basalt fiber in the engineering industries has gained significant interest due to its characteristics such as alkali resistance and enhanced mechanical properties. Similarly, E-glass-fiber-reinforced composites have been widely used in the fabrication of electrically resistive industrial components such as switches, circuit panels, and covering cases. In the present study, the tensile, flexural, thermogravimetric, and low-velocity impact characteristics of various percentages of basalt/E-glass-fiber-reinforced polymer composites fabricated via vacuum-assisted resin transfer molding were investigated. The results show that a higher volume percentage of basalt (39%) significantly enhances the impact resistance up to 45% with a moderate improvement in flexural properties. The higher the vol % of E-glass (40%), the more the tensile and flexural properties are increased, i.e., 185 N/mm2 and 227.87 N/mm2, respectively. It is concluded that by choosing the optimum hybridization method, impact resistance and other mechanical properties can be improved significantly. The thermogravimetric analysis results show that PC313534 (35 vol % basalt and 34 vol % E-glass) possesses the lowest decomposition temperature of 381.10 °C. The results from the present study indicate that the polymer composite fabricated in the present study is suitable for applications where higher structural-load-resistive properties are required. [ABSTRACT FROM AUTHOR]

During the production of fiber-reinforced plastics using resin transfer molding (RTM), various characteristic defects and flaws can occur, such as fiber displacement and fiber waviness. Particularly in high-pressure RTM (HP-RTM), fiber misalignments are generated during infiltration by local peaks in the flow rate, leading to a significant reduction in the mechanical properties. To minimize or avoid this effect, the manufacturing process must be well controlled. Simulative approaches allow for a basic design of the mold filling process; however, due to the high number of influencing variables, the real behavior cannot be exactly reproduced. The focus of this work is on flow front monitoring in an HP-RTM mold using phased array ultrasonic testing. By using an established non-destructive testing instrument, the effort required for integration into the manufacturing process can be significantly reduced. For this purpose, investigations were carried out during the production of test specimens composed of glass fiber-reinforced polyurethane resin. Specifically, a phased array ultrasonic probe was used to record individual line scans over the form filling time. Taking into account the specifications of the probe used in these experiments, an area of 48.45 mm was inspected with a spatial resolution of 0.85 mm derived from the pitch. Due to the aperture that had to be applied to improve the signal-to-noise ratio, an averaging of the measured values similar to a moving average over a window of 6.8 mm had to be considered. By varying the orientation of the phased array probe and therefore the orientation of the line scans, it is possible to determine the local flow velocities of the matrix system during mold filling. Furthermore, process simulation studies with locally varying fiber volume contents were carried out. Despite the locally limited measuring range of the monitoring method presented, conclusions about the global flow behavior in a large mold can be drawn by comparing the experimentally determined results with the process simulation studies. The agreement between the measurement and simulation was thus improved by around 70%. [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]

Process simulation is frequently adopted to facilitate the optimization of the resin transfer molding process. However, it is computationally costly to simulate the multi-physical, multi-scale process, making it infeasible for applications involving huge datasets. In this study, the application of K-nearest neighbors and artificial neural network metamodels is proposed to build predictive surrogate models capable of relating the mold-filling process input-output correlations to assist mold designing. The input features considered are the resin injection location and resin viscosity. The corresponding output features investigated are the number of vents required and the resultant maximum injection pressure. Upon training, both investigated metamodels demonstrated desirable prediction accuracies, with a low prediction error range of 5.0% to 15.7% for KNN metamodels and 6.7% to 17.5% for ANN metamodels. The good prediction results convincingly indicate that metamodeling is a promising option for composite molding applications, with encouraging prospects for data-intensive applications such as process digital twinning. [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]

In the face of the difficulty in achieving high-quality integrated molding of longitudinally and transversely stiffened panels for helicopters by resin-matrix composite materials, we combine the prepreg process and the resin transfer molding (RTM) process to propose a hybrid resin transfer molding (HRTM) for composite stiffened panel structures. The HRTM process uses a mixture of prepreg and dry fabric to lay up a hybrid fiber preform, and involves injecting liquid resin technology. Using this process, a longitudinally and transversely stiffened panel structure is prepared, and the failure modes under compressive load are explored. The results show that at the injection temperature of the RTM resin, the prepreg resin dissolves slightly and has little effect on the viscosity of the RTM resin. Both resins have good miscibility at the curing temperature, which allows for the overall curing of the resin. A removable box core mold for the HRTM molding is designed, which makes it convenient for the mold to be removed after molding and is suitable for the overall molding of the composite stiffened panel. Ultrasonic C-scan results show that the internal quality of the composite laminates prepared using the HRTM process is good. A compression test proves that the composite stiffened panel undergoes sequential buckling deformation in different areas under compressive load, followed by localized debonding and delamination of the skin, and finally failure due to the fracture of the longitudinal reinforcement ribs on both sides. The compressive performance of the test specimen is in good agreement with the finite element simulation results. The verification results show that the HRTM process can achieve high-quality integrated molding of the composite longitudinally and transversely stiffened panel structure. [ABSTRACT FROM AUTHOR]

Polyamide 6 (PA6) thermoplastic composites have higher recyclability potential when compared to conventional thermoset composites. A disruptive liquid molding manufacturing technology named Thermoplastic Resin Transfer Molding (T-RTM) can be used for processing composites due to the low viscosity of the monomers and additives. In this process, polymerization, crystallization and shrinkage occur almost at the same time. If these phenomena are not controlled, they can compromise the reproducibility and homogeneity of the parts. This work studied the influence of packing pressure, as a process variable, throughout the filling and polymerization stages. To assess the process reproducibility and parts' homogeneity, physical, thermal and mechanical properties were analyzed in different areas of neat PA6 and composite parts. This study showed that a two-stage packing pressure can be successfully used to increase parts' homogeneity and process reproducibility. The use of 3.5 bar packing pressure during the polymerization stage resulted in mechanical properties with lower standard deviations, indicating a higher degree of homogeneity of the manufactured parts and higher process reproducibility. These results will be used for establishing the actual state of the technology and will be a base for future process optimization. [ABSTRACT FROM AUTHOR]

Micro-sized Al2O3-modified carbon fiber hybrid reinforced polymer composites (CFHRP) were prepared using the vacuum-assisted resin transfer molding (VARTM) process, and friction and wear tests were performed on an MRTR-1 multifunctional friction and wear tester to study the effect of carbon fiber surface doping with trace amounts of Al2O3 and its content on the tribological properties of carbon fiber reinforced polymer composites. The surface morphology of the composite material was characterized using a three-dimensional confocal laser scanning microscope (LSM). The results showed that under dry friction conditions, the wear behavior of the composite material with micro-Al2O3 added was mainly abrasive wear and adhesive wear. Under the condition of water lubrication, the friction coefficient of the composite material with micro-Al2O3 added was higher than that of the carbon fiber/epoxy resin-based composite material without Al2O3, and the abrasive wear and adhesive wear were significantly reduced. In addition, under the condition of water lubrication, the cooling and boundary lubrication of water played a dominant role in the tribological behavior, so the influence of transfer film on the tribological behavior of the composite material was smaller than that under dry friction conditions. When the micro alumina content is 6%, the friction and wear reduction of CFHRP composite material are improved under water containing conditions. Under dry friction conditions, the content of micrometer alumina has a minimal effect on the change in friction coefficient. [ABSTRACT FROM AUTHOR]

A numerical analysis of the influence of race tracking on dry spots formation and the accuracy of permeability measurement during the resin-transfer-molding process is presented. In the numerical simulation of the mold-filling process, defects are randomly generated, and their effect is assessed by a Monte Carlo simulation method. The effect of race tracking on the unsaturated permeability measurement and dry spots formation is investigated on flat plates. It is observed that the race-tracking defects located near the injection gate increase up to 40% of the value of the measured unsaturated permeability. The race-tracking defects located near the air vents are more likely to generate dry spots, whereas those near the injection gates have a less significant influence on dry spots generation. Depending on vent location, it has for instance been shown that the dry spot area can increase by a factor of 30. Dry spots may be mitigated by placing an air vent at a suitable location based on the numerical analysis results. Moreover, those results may be helpful to determine optimal sensor locations for the on-line control of mold-filling processes. Finally, the approach is successfully applied to a complex geometry. [ABSTRACT FROM AUTHOR]

Dust or condensed water present in harsh outdoor or high-humidity human breath samples are one of the key sources that cause false detection in Micro Electro-Mechanical System (MEMS) gas sensors. This paper proposes a novel packaging mechanism for MEMS gas sensors that utilizes a self-anchoring mechanism to embed a hydrophobic polytetrafluoroethylene (PTFE) filter into the upper cover of the gas sensor packaging. This approach is distinct from the current method of external pasting. The proposed packaging mechanism is successfully demonstrated in this study. The test results indicate that the innovative packaging with the PTFE filter reduced the average response value of the sensor to the humidity range of 75~95% RH by 60.6% compared to the packaging without the PTFE filter. Additionally, the packaging passed the High-Accelerated Temperature and Humidity Stress (HAST) reliability test. With a similar sensing mechanism, the proposed packaging embedded with a PTFE filter can be further employed for the application of exhalation-related, such as coronavirus disease 2019 (COVID-19), breath screening. [ABSTRACT FROM AUTHOR]

The integration of sustainable components in automotive parts is in growing demand. This study involves the entire process, from the extraction of kenaf cellulosic fibers to the fabrication of automotive parts by applying injection molding (sample only) and Resin Transfer Molding (RTM) techniques. Fibers were pretreated, followed by moisture content analysis before composite fabrication. The composite was fabricated by integrating the fibers with polypropylene, maleic anhydride polypropylene (MAPP), unsaturated polyester, and epoxy resin. Mechanical tests were done following ASTM D5083, ASTM D256, and ASTM D5229 standards. The RTM technique was applied for the fabrication of parts with reinforced kenaf long bast fibers. RTM indicated a higher tensile strength of 55 MPa at an optimal fiber content of 40%. Fiber content from 10% to 40% was found to be compatible with or better than the control sample in mechanical tests. Scanning Electron Microscope (SEM) images showed both fiber-epoxy-PE bonding along with normal irregularities in the matrix. The finite element simulations for the theoretical analysis of the mechanical performance characteristics showed higher stiffness and strength in the direction parallel to the fiber orientation. This study justifies the competitiveness of sustainable textile fibers as a reinforcement for plastics to use in composite materials for automotive industries. [ABSTRACT FROM AUTHOR]

This review focuses on the fabrication and mechanical characterization of fibrous composites for engineering applications. Fibrous composites are materials composed of two or more distinct phases, with fibers embedded in a matrix. The properties of these materials depend on the properties of both the fibers and the matrix, as well as the way they are combined and fabricated. The various fabrication methods, along with the process parameters, used to manufacture synthetic and natural fibrous composites for engineering applications, including hand lay-up, compression molding, resin transfer molding, additive manufacturing, etc., are discussed. The mechanical characterization of fibrous composites, including their strength, stiffness, and toughness of both synthetic and natural fibrous composites are discussed. The advantages and disadvantages of fiber reinforcement are discussed, along with their influence on the resulting mechanical characteristics of the composites. It can be observed that the mechanical properties of fibrous composites can be tailored by controlling various factors, such as the fiber orientation, fiber volume fraction, and matrix type. Although fibrous composites offer significant advantages, several challenges hinder their widespread use in engineering applications. These challenges include high manufacturing costs, limited design guidelines, and difficulties in predicting their mechanical behavior under various loading conditions. Therefore, despite their unique properties, these challenges must be overcome for fibrous composites to realize their full potential as high-performance materials. [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]

Despite significant advancements in bio-based natural-fiber-reinforced composites, the recyclability/reprocessing of thermoset composites remains a persistent challenge that needs to be addressed. In the present study, an effort is made to provide a justification for the recyclability/ reprocessing assessment of sandwich composite panels made with 'recyclate' (i.e., recycled flax/bio-based epoxy composite) cores and (flax/bio-based epoxy) skins produced by liquid composite molding. Resin transfer molding and vacuum-assisted resin infusion processes were used to investigate the influence of production processes on mechanical properties. Two different recyclate sizes-4 mm and 10 mm--were used to fabricate sandwich composite panels to study the effect of size on the mechanical properties of the panels. This study aims to compare the qualities of sandwich panels to those of virgin composite panels in terms of their physical (density) and mechanical properties (tensile and flexural). Additionally, the recyclate packing was verified by employing digital microscopy. The results illustrated that the sandwich panels made with the 4 mm recyclates exhibited better mechanical properties compared to those made with the 10 mm recyclates. In comparison with virgin composite panels, the sandwich composite panels made of flax fiber and (flax/epoxy) recyclate exhibited significantly higher flexural moduli, which was attributed to their moments of inertia. This article emphasizes recycling/reprocessing and demonstrates an effective closed-loop approach. Thus, by preserving the structural integrity of recyclates, sandwich panels could be advantageous for semi-structural applications. [ABSTRACT FROM AUTHOR]

This cutting-edge review highlights the fundamentals, design, and manufacturing strategies used for sandwich composites. Sandwich composite structures have the advantages of light weight, high strength, impact resistance, stability, and other superior features for advanced applications. In this regard, different core materials have been used in the sandwich composite structures, such as cellular polymer foam, metallic foam, honeycomb, balsa, tubular, and other core geometries. Among these, honeycomb sandwich composite materials have been effectively applied in space engineering, marine engineering, and construction applications. The foremost manufacturing techniques used for sandwiched composite structures include hand lay-up, press method, prepreg method, vacuum bagging/autoclave, vacuum assisted resin infusion, resin transfer molding, compression molding, pultrusion, three-dimensional (3D) printing, four-dimensional (4D) printing, etc. In advanced composite manufacturing, autoclave processes have been the method of choice for the aerospace industry due to less delamination between plies and easy control of thickness dimensions. Moreover, machining processes used for sandwich composites are discussed in this article. In addition to aerospace, the high-performance significance of sandwiched composite structures is covered mainly in relation to automobile engineering and energy absorption applications. The structure-, fabrication-, and application-related challenges and probable future research directions are also discussed in this article. [ABSTRACT FROM AUTHOR]

Lightweight fiber-reinforced composite structures have been applied in aerospace for decades. Their mechanical properties are crucial for the safety of aircraft and mainly depend on manufacturing technologies such as autoclave, resin transfer molding and automated layup technology. In recent years, the rapid development of intelligent technology such as big data, deep learning, and machine learning has encouraged the development of manufacturing technologies to become low-cost, automatic, and intelligent. However, the current situation and intellectualization of manufacturing technologies is not well summarized. This paper reviews the advances in manufacturing technologies for fiber-reinforced composite structures, including autoclave, out of autoclave, resin transfer molding technologies, automated layup technology and additive manufacturing technology. Then, these technologies are compared in advantages and disadvantages, and their intellectualization development and challenges are also discussed. Finally, the development trend of intelligent manufacturing technologies and intelligent composite structures are discussed. This work can provide a reference for researchers in the related filed. [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]

Carbon fiber reinforced polymers (CFRPs) have spread to a wide range of industries in recent decades, including the automobile, aeronautics, and space industries. Recently, the emergence of new requirements for improved properties and features has become one of the major drivers of the introduction of innovative methodologies and process optimization. In this study, the effect of nanomaterials on the behavior of carbon fiber-reinforced polymer (CFRP) composites was investigated experimentally. The grafting of TiO2 and SiC nanomaterials onto the surface of fibers was performed by mixing nanomaterials in the epoxy resin. CFRPs were manufactured using vacuum assisted resin transfer molding (VARTM) in this study and characterized using mechanical and thermal testing. The primary test parameters were carbon fiber with epoxy resin and 0% nanomaterials by weight. An increase in properties was observed in nanocomposite with 2% wt. of nanomaterials when compared with 0, 0.5, and 1% wt. Between 0 wt.% and 2 wt.%, the tensile strength, flexural strength, impact strength, hardness, and HDT properties were increased by 17%, 39%, 32%, 14% and 21%, respectively, due to the addition of nanomaterials into the resin. [ABSTRACT FROM AUTHOR]

Material as well as process variations in the composites industry are reasons to develop methods for in-line monitoring, which would increase reproducibility of the manufacturing process and the final composite products. Fiber Bragg Gratings (FBGs) have shown to be useful for monitoring liquid-composite molding processes, e.g., in terms of online gel point detection. Existing works however, focus on in-plane strain measurements while out-of-plane residual strain prevails. In order to measure out-of-plane strain, FBG inscribed in highly birefringent fiber (HB FBG) can be used. The purpose of this research is the cure stage detection with (a) FBG inscribed in single mode and (b) FBG inscribed in highly-birefringent side-hole fiber in comparison to the reference gel point detected with an in-mold DC sensor. Results reveal that the curing process is better traceable with HB FBG than with regular FBG. Thus, the use of HB FBG can be a good method for the gel point estimation in the RTM process. [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]

The long cycle of manufacturing continuous carbon fiber-reinforced composite has significantly limited its application in mass vehicle production. High-pressure resin transfer molding (HP-RTM) is the process with the ability to manufacture composites in a relatively short forming cycle (<5 min) using fast reactive resin. The present study aims to investigate the influence of HP-RTM process variables including fiber volume fraction and resin injection flow rate on void characteristics, and flexural properties of manufactured CFRP components based on experiments and numerical simulations. An ultrasonic scanning system and optical microscope were selected to analyze defects, especially void characteristics. Quasi-static bending experiments were implemented for the CFRP specimens with different void contents to find their correlation with material's flexural properties. The results showed that there was also a close correlation between void content and the flexural strength of manufactured laminates, as the flexural strength decreased by around 8% when the void content increased by ~0.5%. In most cases, the void size was smaller than 50 μm. The number of voids substantially increased with the increase in resin injection flow rate, while the potential effect of resin injection flow rate was far greater than the effect of fiber volume fraction on void contents. To form complicated CFRP components with better mechanical performance, resin injection flow rate should be carefully decided through simulations or preliminary experiments. [ABSTRACT FROM AUTHOR]

Natural nanofibers are widely used in the field of medicine, but the low strength of these nanofibers is one of the major concerns. A number of factors, importantly the composition, affect the strength of natural nanofibers. The purpose of the current study is to ascertain the effect of the composition of natural nanofibers on the strength of hybrid composites formed using these nanofibers. Hybrid composites formed using 32% volume glass fibre with optimized volume fraction of 0.5% of pure Cellulose Acetate (CA), and 0.5% CA + Hemp Seed (HS) for this study to carry out the analysis. Hybrid composites were produced with vacuum-assisted resin transfer molding (VARTM) by collecting natural nanofibers, produced using the electrospinning process, over glass fiber mats. The electrospinning process was carried out with 12 kV, 10 cm tip to the collector gap, and 12% concentration of the solution. The tensile strength of the hybrid composites was measured using the universal testing machine (UTM). The results showed that the diameter of the electrospun nanofiber varied between 50 and 1400 nm and was affected by solution concentration, voltage, tip-to-collector distance, flow rate, and inclusion of HS in CA. The inclusion of HS in CA, for all compositions, decreased the fiber diameter and caused the formation of beads prominently at higher concentrations. Hybrid composites formed from nanofibers produced using CA and HS showed higher elastic modulus (232 MPa) and tensile strength (20.4 GPa) as compared with nanofibers produced using CA only (elastic modulus = 110 MPa and 13.7 GPa). [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]

In this study, carbon fiber-reinforced polyamide 6 composites were prepared by in situ polymerization via vacuum-assisted resin transfer molding (VARTM) in order to evaluate the effect of processing parameters on the mechanical properties and mold filling ratio. At the molding temperature of 140 °C, a high degree of polymerization of the monomer and impregnation of the resin in the preform were empirically observed. The effect of the molding temperature was analyzed by monitoring the mechanical properties (tensile, bending, and impact strength). The mechanical tests showed that the tensile strength, bending strength, bending modulus, and impact strength were highest for the specimens molded at 140 °C compared to those treated at other temperatures. The experimental results were compared with numerical simulations in order to evaluate the relationship between the mold filling ratio and filling time for large-scale automotive parts with various shapes and sizes. The comparison is of great significance for predicting the mold design as well as processing parameters for large-scale automotive parts. [ABSTRACT FROM AUTHOR]

When thermoplastic resin-toughened carbon fiber (CF) composites are formed by liquid resin transfer molding (RTM), the conventional methods cannot be used to set the fabric preform, which affects the overall mechanical properties of the composites. To address this challenge, the benzoxazine-based tackifier BT5501A was designed, a preforming–toughening bifunctional CF fabric was fabricated by employing thermoplastic polyaryletherketone (PEK-C), and an aviation RTM-grade bismaleimide (BMI) resin was used as the matrix to study the effect of the benzoxazine-based tackifier on the thermal curing property and heat resistance of the resin matrix. Furthermore, the preforming and toughening effects on the bifunctional CF fabric reinforced the BMI resin composites. The tackifier BT5501A has good process operability. The application of this tackifier can advance the thermal curing temperature of the BMI resin matrix and decrease the glass transition temperature of the resin, compared to that of the pure BMI resin. Furthermore, when the tackifier was added into the CF/PEK-C/BMI composites, the obtained CF/BT5501A/PEK-C/BMI composites had comparable compression strength after impact, pit depth, and damage area, compared to the CF/PEK-C/BMI composites, while the tackifier endowed the fabric preform with an excellent preforming effect. [ABSTRACT FROM AUTHOR]

In this contribution, the influence of the reaction injection moulding process on the thermomechanical material behaviour of aliphatic hexamethylene diisocyanate (HDI) based fast curing polyurethane is demonstrated. Uniaxial tensile tests, temperature-frequency dependent dynamic mechanical thermal analysis (DMTA) and Differential Scanning Calorimetry (DSC) are used to show the differences in properties for ten different sets of process parameters. The mould and resin components temperature, the mass flow during the filling process and the residence time during the reaction process of the polyurethane are varied in several stages. Further experiments to determine the molar mass of the molecular chain between two crosslinking points of the polyurethane are used to explain the process influences on the thermomechanical properties. Thus, a direct correlation between manufacturing and material properties is shown. In addition, the mutual effect of the different parameters and their overall influence on the material behaviour is presented. [ABSTRACT FROM AUTHOR]

Due to the high design freedom and weight specific properties carbon fiber reinforced plastics (CFRP) offer significant potential in light-weighting applications, specifically in the automotive sector. The demand for medium to high production quantities with consistent material properties has paved the way for the use of high-pressure resin transfer molding (HP-RTM). Due to high experimental cost and number of the operational parameters the development of numerical simulations to predict part quality is growing. Despite this, erroneous assumptions and simplifications limit the application of HP-RTM models, specifically with regards to the energy models used to model the heat transfer occurring during infiltration. The current work investigates the operating parameters at which the thermal non-equilibrium energy model's increased computational cost and complexity is worth added accuracy. It was found that in nearly all cases, using the thermal non-equilibrium is required to obtain an accurate prediction of the temperature development and resulting final properties within the mold after the infiltration process. [ABSTRACT FROM AUTHOR]

Composite materials have gained increased usage due to their unique characteristic of a high-stiffness-to-weight ratio. High-performing composite materials are produced in the autoclave by applying elevated pressure and temperature. However, the process is characterized by numerous disadvantages, such as long cycle time, massive investment, costly tooling, and excessive energy consumption. As a result, composite manufacturers seek a cheap alternative to reduce cost and increase productivity. The out-of-autoclave (OoA) process manufactures composites by applying vacuum, pressure, and heat outside of the autoclave. This review discusses the common out-of-autoclave processes for various applications. The theoretical and practical merits and demerits are presented, and areas for future research are discussed. [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]

Although aramid fiber has the advantage of excellent chemical and mechanical properties, the performance of the composites may be reduced due to the low interfacial adhesion between the fabric and the matrix. The surface of the aramid fiber was modified to improve the interfacial properties. The surface of the aramid fibers was treated with ZnCl2 and polydopamine. After the pretreated fabrics were made into a composite material by the vacuum-assisted resin transfer molding (VARTM) process, their mechanical performance was investigated. The highest impact energy was shown in the concentration of 6 wt% ZnCl2 and 1.5 g/L polydopamine, which is 20% better than that of the untreated material. In the bending strength, the condition of 1.5 g/L polydopamine resulted in the highest value and increased by 13% compared to the untreated material. The hybrid surface treatment of ZnCl2 and polydopamine did not significantly affect the tensile strength. [ABSTRACT FROM AUTHOR]

This work aims to analyze theoretically and with laboratory tests the sensitivity of high-frequency GPR (Ground-Penetrating Radar) to resin injections used in the building and ornamental stone industries to repair marble blocks before final slab cutting. We simulate uniform fractures in the laboratory using small regular marble blocks and we compare the results of GPR tests with the analytical model of the thin bed reflections. We performed two series of GPR surveys with a 3 GHz antenna, progressively increasing the fracture thickness from 0.25 mm to 16 mm, to analyze the results on two simulated conditions: open fracture and repaired fracture. The repaired condition was simulated by substituting the resin layer with polyvinyl chloride (PVC) sheets because the permittivity of PVC is quite similar to the permittivity of epoxy resin. According to the analytical models, when a thin air-filled fracture is filled with resin, the received signal amplitude is expected to decrease by 33% (26% if resin is simulated with PVC). The results showed a very good match between the predictions and the real data observations when the fracture is thicker than 4 mm. Although the analytical and laboratory results show some deviations when the fracture is thinner than 4 mm, the qualitative trend of the amplitude variations is still consistent with the predictions and the 3 GHz antenna can resolve the change in the filling material down to the minimum tested thickness (0.25 mm). As a result, our findings validate the GPR method as a proper tool for nondestructive quality control of resin injections in marble fractures. [ABSTRACT FROM AUTHOR]

Edge race-tracking is a frequently reported issue during resin transfer molding. It is caused by highly permeable channels and areas between the preform edge and cavity, which can significantly change the preform impregnation pattern. To date, information is scarce on the effect of edge racetracking in compression resin transfer molding (CRTM). To close this gap, laboratory equipment was developed to study the CRTM preform impregnation via flow visualization experiments. The preform was thereby encapsulated in thin thermoplastic films sealing its impregnation. Film-sealed compression resin transfer molding (FS-CRTM) experiments of preforms with a small geometrical aspect ratio showed fast filling of the injection gap and a subsequent through-thickness preform impregnation. Creating an edge race-tracking channel, an additional lateral in-plane flow from the channel towards the preform center was observed, initiating soon after the injection started and caused by the spatial connection between the injection gap and the race-tracking channel. To diminish edge race-tracking, a passive flow control strategy was implemented via a split design of the upper tool to spatially isolate the injection gap from the channel and to pre-compact the preform edge. A delayed and reduced lateral race-tracking flow was observed, showing that the passive flow control strategy increases the process robustness of FS-CRTM regarding edge race-tracking effects. [ABSTRACT FROM AUTHOR]

In this work, a supervised machine learning (ML) model was developed to detect flow disturbances caused by the presence of a dissimilar material region in liquid moulding manufacturing of composites. The machine learning model was designed to predict the position, size and relative permeability of an embedded rectangular dissimilar material region through use of only the signals corresponding to an array of pressure sensors evenly distributed on the mould surface. The burden of experimental tests required to train in an efficient manner such predictive models is so high that favours its substitution with synthetically-generated simulation datasets. A regression model based on the use of convolutional neural networks (CNN) was developed and trained with data generated from mould-filling simulations carried out through use of OpenFoam as numerical solver. The evolution of the pressure sensors through the filling time was stored and used as grey-level images containing information regarding the pressure, the sensor location within the mould and filling time. The trained CNN model was able to recognise the presence of a dissimilar material region from the data used as inputs, meeting accuracy expectation in terms of detection. The purpose of this work was to establish a general framework for fully-synthetic-trained machine learning models to address the occurrence of manufacturing disturbances without placing emphasis on its performance, robustness and optimization. Accuracy and model robustness were also addressed in the paper. The effect of noise signals, pressure sensor network size, presence of different shape dissimilar regions, among others, were analysed in detail. The ability of ML models to examine and overcome complex physical and engineering problems such as defects produced during manufacturing of materials and parts is particularly innovative and highly aligned with Industry 4.0 concepts. [ABSTRACT FROM AUTHOR]

A drastically growing requirement of electronic packages with an increasing level of complexity poses newer challenges for the competitive manufacturing industry. Coupled with harsher operating conditions, these challenges affirm the need for encapsulated board-level (2nd level) packages. To reduce thermo-mechanical loads induced on the electronic components during operating cycles, a conformal type of encapsulation is gaining preference over conventional glob-tops or resin casting types. The availability of technology, the ease of automation, and the uncomplicated storage of raw material intensifies the implementation of thermoset injection molding for the encapsulation process of board-level packages. Reliability case studies of such encapsulated electronic components as a part of board-level packages become, thereupon, necessary. This paper presents the reliability study of exemplary electronic components, surface-mounted on printed circuit boards (PCBs), encapsulated by the means of thermoset injection molding, and subjected to cyclic thermal loading. The characteristic lifetime of the electronic components is statistically calculated after assessing the probability plots and presented consequently. A few points of conclusion are summarized, and the future scope is discussed at the end. [ABSTRACT FROM AUTHOR]

Experimental studies are presented on quasi-static tensile and compressive loading of composites hybridised at two levels: intraply and interply. Consistent reinforcements in the form of novel unidirectional fabrics were developed using T700SC carbon and E-CR glass fibres. Composites were manufactured using Resin Transfer Moulding process with epoxy resin and characterised to ensure consistency and comparability, further enabling easier understanding and confirmation of hybrid effect in a reliable way. Failure strain in tension for interply hybrid revealed a positive hybrid effect of +7.4%, while interply hybrid showed a negative hybrid effect of [ABSTRACT FROM AUTHOR]

The activated anionic ring opening polymerization of ε-caprolactam to polyamide 6 is highly sensitive to external influences such as water. Based on an initial theory, preliminary reaction kinetic tests are carried out with the aim of compensating the influence of the water by increasing the activator and catalyst concentration. Different formulations of activator and catalyst were studied to understand the influence of water on the concentration of activator and catalyst. It was found that the compensation of added water with activator and catalyst restores the original reaction time. The test plates produced are examined with regard to their mechanical characteristics and the polymer properties. The results of the mechanical characterization show no significant impairment after compensation of the added water. The physical properties of the matrix show degradation with repeated compensation. However, the residual ε-caprolactam content remains below the critical value of 1% for three of the four investigated formulations. [ABSTRACT FROM AUTHOR]

Resin transfer molding (RTM) technologies are widely used in automotive, marine, and aerospace applications. The need to evaluate the impact of design and production critical choices, also in terms of final costs, leads to the wider use of numerical simulation in the preliminary phase of component development. The main issue for accurate RTM analysis is the reliable characterization of the involved materials. The aim of this paper is to present a validated methodology for material characterization to be implemented and introduce data elaboration in the ESI PAM-RTM software. Experimental campaigns for reinforcement permeabilities and resin viscosity measurement are presented and discussed. Finally, the obtained data are implemented in the software and then compared to experimental results in order to validate the described methodology. [ABSTRACT FROM AUTHOR]