Search results for: vacuum assisted resin transfer molding (VARTM)

Authors: Tzai-Shiung Li, Wen-Bin Young

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The wind turbine blade sustains various kinds of loadings during the operating and parking state. Due to the increasing size of the wind turbine blade, it is important to arrange the composite materials in a sufficient way to reach the optimal utilization of the material strength. In the fabrication process of the vacuum assisted resin transfer molding, the fiber content of the turbine blade depends on the vacuum pressure. In this study, a design of the fiber layup for the vacuum assisted resin transfer molding is conducted to achieve the efficient utilization the material strength. This design is for the wind turbine blade consisting of shell skins with or without the spar structure.

Keywords: resin film infiltration, vacuum assisted resin transfer molding process, wind turbine blade, composite materials

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Authors: Nagri Sateesh, Kundavarapu Vengalrao, Kopparthi Phaneendra Kumar

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Vacuum assisted resin transfer molding (VARTM) is one of the manufacturing technique that is viable for production of fiber reinforced polymer composite components suitable for aerospace, marine and commercial applications. However, the repeatable quality of the product can be achieved by critically fixing the process parameters such as Vacuum Pressure (VP) and permeability of the preform. The present investigation is aimed at studying the effect of permeability for production of Glass Fiber Reinforced Plastic (GFRP) components with consistent quality. The VARTM mould is made with an acrylic transparent top cover to observe and record the resin flow pattern. Six layers of randomly placed glass fiber under five different vacuum pressures VP1 = 0.013, VP2 = 0.026, VP3 = 0.039, VP4 = 0.053 and VP5 = 0.066 MPa were studied. The laminates produced by this process under the above mentioned conditions were characterized with ASTM D procedures so as to study the effect of these process parameters on the quality of the laminate. Moreover, as mentioned there is a considerable effect of permeability on the impact strength and the void content in the laminates under different vacuum pressures. SEM analysis of the impact tested fractured GFRP composites showed the bonding of fiber and matrix.

Keywords: permeability, vacuum assisted resin transfer molding (VARTM), ASTM D standards, SEM

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Authors: Dingding Chen, Kazuo Arakawa, Masakazu Uchino, Changheng Xu

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Vacuum assisted resin transfer moulding (VARTM) is a promising manufacture process for making large and complex fiber reinforced composite structures. However, the complexity of the flow of the resin in the infusion stage usually leads to nonuniform property distribution of the produced composite part. In order to control the flow of the resin, the situation of flow should be mastered. For the safety of the usage of the produced composite in practice, the understanding of the property distribution is essential. In this paper, we did some trials on monitoring the resin infusion stage and evaluation for the fiber volume fraction distribution of the VARTM produced composite using the digital image correlation methods. The results show that 3D-DIC is valid on monitoring the resin infusion stage and it is possible to use 2D-DIC to estimate the distribution of the fiber volume fraction on a FRP plate.

Keywords: digital image correlation, VARTM, FRP, fiber volume fraction

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Authors: Jayaraman Muniyappan, Bachchan Kr Mishra, Gautam Salkar, Swetha Manian Sridhar

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Vacuum Assisted Resin Transfer Molding (VARTM), a cost effective method of Liquid Composite Molding (LCM), is a single step process where the resin, at atmospheric pressure, is infused through a preform that is maintained under vacuum. This hydrodynamic pressure gradient is responsible for the flow of resin through the dry fabric preform. The current study has a slight variation to traditional VARTM, wherein, the resin infuses through the fabric placed on a heated mold to reduce its viscosity. The saturated preform is subjected to a cure cycle where the resin hardens as it undergoes curing. During this cycle, an uneven temperature distribution through the thickness of the composite and excess exothermic heat released due to different cure rates result in non-uniform curing. Additionally, there is a difference in thermal expansion coefficient between fiber and resin in a given plane and between adjacent plies. All these effects coupled with orthotropic coefficient of thermal expansion of the composite give rise to process-induced stresses in the laminate. Such stresses lead to part deformation when the laminate tries to relieve them as the part is released off the mold. The current study looks at simulating resin infusion, cure kinetics and the structural response of composite laminate subject to process-induced stresses.

Keywords: cure kinetics, process-induced stresses, thermal expansion coefficient, vacuum assisted resin transfer molding

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Authors: M. R. Abusrea, Shiyi Jiang, Dingding Chen, Kazuo Arakawa

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Novel wind-lens turbine designs can augment power output. Vacuum-Assisted Resin Transfer Molding (VARTM) is used to form large and complex structures from a Carbon Fiber Reinforced Polymer (CFRP) composite. Typically, wind-lens turbine structures are fabricated in segments, and then bonded to form the final structure. This paper introduces five new adhesive joints, divided into two groups: One is constructed between dry carbon and CFRP fabrics, and the other is constructed with two dry carbon fibers. All joints and CFRP fabrics were made in our laboratory using VARTM manufacturing techniques. Specimens were prepared for tensile testing to measure joint performance. The results showed that the second group of joints achieved a higher tensile strength than the first group. On the other hand, the tensile fracture behavior of the two groups showed the same pattern of crack originating near the joint ends followed by crack propagation until fracture.

Keywords: adhesive joints, CFRP, VARTM, resin transfer molding

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Authors: Alok Srivastava, Vidit Gupta, Aparna Singh, Chandra Sekher Yerramalli

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Carbon-fiber epoxy composites show extremely high modulus and strength in the uniaxial direction. However, they are prone to fail under low load in transverse direction due to the weak nature of the interface between the carbon-fiber and epoxy. In the current study, we have coated graphene nano-platelets (GNPs) on the carbon-fibers in an attempt to strengthen the interface/interphase between the fiber and the matrix. Vacuum Assisted Resin Transfer Moulding (VARTM) has been used to make the laminates of eight cross-woven fabrics. Tensile, flexural and fracture toughness tests have been performed on pristine carbon-fiber composite (P-CF), GNP coated carbon-fiber composite (GNP-CF) and functionalized-GNP coated carbon-fiber composite (F-GNP-CF). The tensile strength and flexural strength values are pretty similar for P-CF and GNP-CF. The micro-structural examination of the GNP coated carbon-fibers, as well as the fracture surfaces, have been carried out using scanning electron microscopy (SEM). The micrographs reveal the deposition of GNPs onto the carbon fibers in transverse and longitudinal direction. Fracture surfaces show the debonding and pull outs of the carbon fibers in P-CF and GNP-CF samples.

Keywords: carbon fiber, graphene nanoplatelets, strength, VARTM, Vacuum Assisted Resin Transfer Moulding

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Authors: Alak Kumar Patra, Nilanjan Mitra

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Interface fracture toughness of glass-epoxy (G/E) PVC core sandwich composite with and without MWCNT has been investigated through experimental methods. Results demonstrate an improvement in interface fracture toughness values (GC) of samples with a certain percentages of MWCNT. In addition, dispersion of MWCNT in epoxy resin through sonication followed by mixing of hardener and vacuum assisted resin transfer method (VARTM) used in this study is an easy and cost effective methodology in comparison to previously adopted other methods limited to laminated composites. The study also identifies the optimum weight percentage of MWCNT addition in the resin system for maximum performance gain in interfacial fracture toughness. The results are supported by high resolution transmission electron microscope (HRTEM) analysis and fracture micrograph of field emission scanning electron microscope (FESEM) investigation.

Keywords: carbon nanotube, foam, glass-epoxy, interfacial fracture, sandwich composite

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Authors: Zachary N. Wing

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Compared to autoclave based processes, Resin Transfer Molding (RTM) offers several key advantages. This includes high internal and external complexity, less waste, lower volatile emissions, higher production rates, and excellent surface finish. However, the injection of high pressure-high temperature resin presents a tooling challenge in cases where trapped geometries exist. Tooling materials that can sustain these conditions and be easily removed would expand the use of RTM. We have performed research on developing an RTM suitable tooling material called 'RTMCore' for use in forming trapped geometries. RTMCore tooling materials can withstand the injection of high temperature-high pressure resin but be easily removed with tap water. RTM properties and performance capabilities are reviewed against other washout systems. Our research will cover the preliminary characterization of tooling system properties, mechanical behavior, and initial results from an RTM manufacturing trial. Preliminary results show the material can sustain pressures greater than 13 MPa and temperatures greater than 150°C.

Keywords: RTM, resin transfer molding, trapped geometries, washout tooling

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Authors: Qiong Tian, Lifeng Zhang, Demei Yu, Ajit D. Kelkar

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Low specific weight and high strength is the basic requirement for aerospace materials. Fiber-reinforced epoxy resin composites are attractive materials for this purpose. Boron nitride nanoparticles (BNNPs) have good radiation shielding capacity, which is very important to aerospace materials. Herein a processing route for an advanced hybrid composite material is demonstrated by introducing dispersed BNNPs in standard prepreg manufacturing. The hybrid materials contain three parts: E-fiberglass, an aerospace-grade epoxy resin system, and BNNPs. A vacuum assisted resin transfer molding (VARTM) was utilized in this processing. Two BNNP functionalization approaches are presented in this study: (a) covalent functionalization with 3-aminopropyltriethoxysilane (KH-550); (b) non-covalent functionalization with cetyltrimethylammonium bromide (CTAB). The functionalized BNNPs were characterized by Fourier-transform infrared spectroscopy (FT-IR), X-ray diffraction(XRD) and scanning electron microscope (SEM). The results showed that BN powder was successfully functionalized via the covalent and non-covalent approaches without any crystal structure change and big agglomerate particles were broken into platelet-like nanoparticles (BNNPs) after functionalization. Compared to pristine BN powder, surface modified BNNPs could result in significant improvement in mechanical properties such as tensile, flexural and compressive strength and modulus. CTAB functionalized BNNPs (CTAB-BNNPs) showed higher tensile and flexural strength but lower compressive strength than KH-550 functionalized BNNPs (KH550-BNNPs). These reinforcements are mainly attributed to good BNNPs dispersion and interfacial adhesion between epoxy matrix and BNNPs. This study reveals the potential in improving mechanical properties of BNNPs-containing composites laminates through surface functionalization of BNNPs.

Keywords: boron nitride, epoxy, functionalization, prepreg, composite

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Authors: Andrew Hardman, Alistair T. McIlhagger, Edward Archer

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A degree of research has been undertaken in the determination of 3D textile preforms behaviour to compression with direct comparison to 2D counterparts. Multiscale simulations have been developed to try and accurately analyse the behaviour of varying architectures post-consolidation. However, further understanding is required to experimentally identify the mechanisms and deformations that exist upon conforming to a complex contour. Due to the complexity of 3D textile preforms, determination of yarn behaviour to a complex contour is assessed through consolidation by means of vacuum assisted resin transfer moulding (VARTM), and the resulting mechanisms are investigated by micrograph analysis. Varying architectures; with known areal densities, pic density and thicknesses are assessed for a cohesive study. The resulting performance of each is assessed qualitatively as well as quantitatively from the perspective of material in terms of the change in representative unit cell (RVE) across the curved beam contour, in crimp percentage, tow angle, resin rich areas and binder distortion. A novel textile is developed from the resulting analysis to overcome the observed deformations.

Keywords: comformability, compression, binder architecture, 3D weaving, textile preform

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Authors: Burcu Kaya, Jan-Martin Kaiser, Karl-Friedrich Becker, Tanja Braun, Klaus-Dieter Lang

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Quality of the molded packages is strongly influenced by the process parameters of the transfer molding. To achieve a better package quality and a stable transfer molding process, it is necessary to understand the influence of the process parameters on the package quality. This work aims to comprehend the relationship between the process parameters, and to identify the optimum process parameters for the transfer molding process in order to achieve less voids and wire sweep. To achieve this, a DoE is executed for process optimization and a regression analysis is carried out. A systematic approach is represented to generate models which enable an estimation of the number of voids and wire sweep. Validation experiments are conducted to verify the model and the results are presented.

Keywords: dielectric analysis, electronic packages, epoxy molding compounds, transfer molding process

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Authors: Nisrin R. Abdelal, Steven L. Donaldson

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Composite materials are widely used in aviation industry due to their superior properties; however, they are susceptible to delamination. Through-thickness stitching is one of the techniques to alleviate delamination. Kevlar is one of the most common stitching materials; in contrast, it is expensive and presents stitching fabrication challenges. Therefore, this study compares the performance of Kevlar with an inexpensive and easy-to-use nylon fiber in stitching to alleviate delamination. Three laminates of unidirectional carbon fiber-epoxy composites were manufactured using vacuum assisted resin transfer molding process. One panel was stitched with Kevlar, one with nylon, and one unstitched. Mode I interlaminar fracture tests were carried out on specimens from the three composite laminates, and the results were compared. Fractographic analysis using optical and scanning electron microscope were conducted to reveal the differences between stitching with Kevlar and nylon on the internal microstructure of the composite with respect to the interlaminar fracture toughness values.

Keywords: carbon, delamination, Kevlar, mode I, nylon, stitching

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Authors: Maria Fonseca, Ana Branco, Joao Graca, Rui Mendes, Pedro Mimoso

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The present work is focused on the production of a carbon composite element for cycling through different techniques, namely, blow-molding and high-pressure resin transfer injection (HP-RTM). The main objective of this work is to compare both processes to produce carbon composite elements for the cycling industry. It is well known that the carbon composite components for cycling are produced mainly through blow-molding; however, this technique depends strongly on manual labour, resulting in a time-consuming production process. Comparatively, HP-RTM offers a more automated process which should lead to higher production rates. Nevertheless, a comparison of the elements produced through both techniques must be done, in order to assess if the final products comply with the required standards of the industry. The main difference between said techniques lies in the used material. Blow-moulding uses carbon prepreg (carbon fibres pre-impregnated with a resin system), and the material is laid up by hand, piece by piece, on a mould or on a hard male. After that, the material is cured at a high temperature. On the other hand, in the HP-RTM technique, dry carbon fibres are placed on a mould, and then resin is injected at high pressure. After some research regarding the best material systems (prepregs and braids) and suppliers, an element was designed (similar to a handlebar) to be constructed. The next step was to perform FEM simulations in order to determine what the best layup of the composite material was. The simulations were done for the prepreg material, and the obtained layup was transposed to the braids. The selected material was a prepreg with T700 carbon fibre (24K) and an epoxy resin system, for the blow-molding technique. For HP-RTM, carbon fibre elastic UD tubes and ± 45º braids were used, with both 3K and 6K filaments per tow, and the resin system was an epoxy as well. After the simulations for the prepreg material, the optimized layup was: [45°, -45°,45°, -45°,0°,0°]. For HP-RTM, the transposed layup was [ ± 45° (6k); 0° (6k); partial ± 45° (6k); partial ± 45° (6k); ± 45° (3k); ± 45° (3k)]. The mechanical tests showed that both elements can withstand the maximum load (in this case, 1000 N); however, the one produced through blow-molding can support higher loads (≈1300N against 1100N from HP-RTM). In what concerns to the fibre volume fraction (FVF), the HP-RTM element has a slightly higher value ( > 61% compared to 59% of the blow-molding technique). The optical microscopy has shown that both elements have a low void content. In conclusion, the elements produced using HP-RTM can compare to the ones produced through blow-molding, both in mechanical testing and in the visual aspect. Nevertheless, there is still space for improvement in the HP-RTM elements since the layup of the braids, and UD tubes could be optimized.

Keywords: HP-RTM, carbon composites, cycling, FEM

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Authors: Dattaji K. Shinde, Ajit D. Kelkar

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Interlaminar shear strength (ILSS) of fiber reinforced polymer composite is an important property for most of the structural applications. Matrix modification is an effective method used to improve the interlaminar shear strength of composite. In this paper, EPON 862/w epoxy system was modified using Tetraethyl orthosilicate (TEOS) electrospun nanofibers (ENFs) which were produced using electrospinning method. Unmodified and nanofibers modified resins were used to fabricate glass fiber reinforced polymer composite (GFRP) using H-VARTM method. The ILSS of the Glass Fiber Reinforced Polymeric Composites (GFRP) was investigated. The study shows that introduction of TEOS ENFs in the epoxy resin enhanced the ILSS of GFRPby 15% with 0.6% wt. fraction of TEOS ENFs.

Keywords: electrospun nanofibers, H-VARTM, interlaminar shear strength, matrix modification

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Authors: Emre Kara, Metehan Demir, Şura Karakuzu, Kadir Koç, Ahmet F. Geylan, Halil Aykul

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While the polymeric foam cored sandwiches have been realized for many years, recently there is a growing and outstanding interest on the use of sandwiches consisting of aluminum foam core because of their some of the distinct mechanical properties such as high bending stiffness, high load carrying and energy absorption capacities. These properties make them very useful in the transportation industry (automotive, aerospace, shipbuilding industry), where the "lightweight design" philosophy and the safety of vehicles are very important aspects. Therefore, in this study, the sandwich panels with aluminum alloy foam core and various types and thicknesses of glass fiber reinforced polymer (GFRP) skins produced via Vacuum Assisted Resin Transfer Molding (VARTM) technique were obtained by using a commercial toughened epoxy based adhesive with two components. The aim of this contribution was the analysis of the bending response of sandwiches with various glass fiber reinforced polymer skins. The three point bending tests were performed on sandwich panels at different values of support span distance using a universal static testing machine in order to clarify the effects of the type and thickness of the GFRP skins in terms of peak load, energy efficiency and absorbed energy values. The GFRP skins were easily bonded to the aluminum alloy foam core under press machine with a very low pressure. The main results of the bending tests are: force-displacement curves, peak force values, absorbed energy, collapse mechanisms and the influence of the support span length and GFRP skins. The obtained results of the experimental investigation presented that the sandwich with the skin made of thicker S-Glass fabric failed at the highest load and absorbed the highest amount of energy compared to the other sandwich specimens. The increment of the support span distance made the decrease of the peak force and absorbed energy values for each type of panels. The common collapse mechanism of the panels was obtained as core shear failure which was not affected by the skin materials and the support span distance.

Keywords: aluminum foam, collapse mechanisms, light-weight structures, transport application

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Authors: Emre Kara, Şura Karakuzu, Ahmet Fatih Geylan, Metehan Demir, Kadir Koç, Halil Aykul

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The material selection in the design of the sandwich structures is very crucial aspect because of the positive or negative influences of the base materials to the mechanical properties of the entire panel. In the literature, it was presented that the selection of the skin and core materials plays very important role on the behavior of the sandwich. Beside this, the use of the correct adhesive can make the whole structure to show better mechanical results and behavior. By this way, the sandwich structures realized in the study were obtained with the combination of aluminum foam core and three different glass fiber reinforced polymer (GFRP) skins using two different commercial adhesives which are based on flexible polyurethane and toughened epoxy. The static and dynamic tests were already applied on the sandwiches with different types of adhesives. In the present work, the static three-point bending tests were performed on the sandwiches having an aluminum foam core with the thickness of 15 mm, the skins with three different types of fabrics ([0°/90°] cross ply E-Glass Biaxial stitched, [0°/90°] cross ply E-Glass Woven and [0°/90°] cross ply S-Glass Woven which have same thickness value of 1.75 mm) and two different commercial adhesives (flexible polyurethane and toughened epoxy based) at different values of support span distances (L= 55, 70, 80, 125 mm) by aiming the analyses of their flexural performance. The skins used in the study were produced via Vacuum Assisted Resin Transfer Molding (VARTM) technique and were easily bonded onto the aluminum foam core with flexible and toughened adhesives under a very low pressure using press machine with the alignment tabs having the total thickness of the whole panel. The main results of the flexural loading are: force-displacement curves obtained after the bending tests, peak force values, absorbed energy, collapse mechanisms, adhesion quality and the effect of the support span length and adhesive type. The experimental results presented that the sandwiches with epoxy based toughened adhesive and the skins made of S-Glass Woven fabrics indicated the best adhesion quality and mechanical properties. The sandwiches with toughened adhesive exhibited higher peak force and energy absorption values compared to the sandwiches with flexible adhesive. The core shear mode occurred in the sandwiches with flexible polyurethane based adhesive through the thickness of the core while the same mode took place in the sandwiches with toughened epoxy based adhesive along the length of the core. The use of these sandwich structures can lead to a weight reduction of the transport vehicles, providing an adequate structural strength under operating conditions.

Keywords: adhesive and adhesion, aluminum foam, bending, collapse mechanisms

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Authors: Dylan Shiting Lu, Samson Okello, Anita Chunyan Wei, Daniel Xiao Li

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Mammotome vacuum-assisted breast biopsy (MVB) introduced in 1995 can be used for the removal of benign breast lesions. Whether or not MVB is a better option compared to conventional open surgery is inconclusive. We aim to compare the clinical and patient-related outcomes between MVB and open surgery to remove benign breast tumors less than 5 cm in women. We searched English and Chinese electronic databases with the keywords of Mammotome, clinical trial (CT), vacuum-assisted breast biopsy for studies comparing MVB and open surgery until May 2021. We performed a systematic review and random-effects meta-analysis to compare incision size, operation time, intraoperative blood loss, healing time, scar length, patient satisfaction, postoperative hematoma rate, wound infection rate, postoperative ecchymosis, and postoperative sunken skin among those who have Mammotome and those who have surgery. Our analysis included nine randomized CTs with 1155 total patients (575 Mammotome, 580 surgery) and mean age 40.32 years (standard deviation 3.69). We found statistically significant favorable outcomes for Mammotome including blood loss (ml) [standardized mean difference SMD -5.03, 95%CI (-7.30, -2.76)], incision size (cm) [SMD -12.22, 95%CI (-17.40, -7.04)], operation time (min) [SMD -6.66, 95%CI (-9.01, -4.31)], scar length (cm) [SMD -7.06, 95%CI (-10.76, -3.36)], healing time (days) [SMD -6.57, 95%CI (-10.18, -2.95)], and patient satisfaction [relative risk RR 0.38, 95%CI (0.13, 1.08)]. In conclusion, Mammotome vacuum-assisted breast biopsy compared to open surgery shows better clinical and patient-related outcomes. Further studies should be done on whether or not MVB is a better option for benign breast tumors excision.

Keywords: clinical and patient outcomes, open surgery, Mammotome vacuum-assisted breast biopsy, meta-analysis

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Authors: Ssu-Han Chen, Der-Baau Perng

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Molding process in IC manufacturing secures chips against the harms done by hot, moisture or other external forces. While a chip was being molded, defects like cracks, dilapidation, or voids may be embedding on the molding surface. The molding surfaces the study poises to treat and the ones on the market, though, differ in the surface where texture similar to defects is everywhere. Manual inspection usually passes over low-contrast cracks or voids; hence an automatic optical inspection system for molding surface is necessary. The proposed system is consisted of a CCD, a coaxial light, a back light as well as a motion control unit. Based on the property of statistical textures of the molding surface, a series of digital image processing and classification procedure is carried out. After training of the parameter associated with above algorithm, result of the experiment suggests that the accuracy rate is up to 93.75%, contributing to the inspection quality of IC molding surface.

Keywords: molding surface, machine vision, statistical texture, discrete Fourier transformation

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Authors: Emre Kara, Ahmet Fatih Geylan, Kadir Koç, Şura Karakuzu, Metehan Demir, Halil Aykul

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The structures obtained with the use of sandwich technologies combine low weight with high energy absorbing capacity and load carrying capacity. Hence, there is a growing and markedly interest in the use of sandwiches with aluminium foam core because of very good properties such as flexural rigidity and energy absorption capability. The static (bending and penetration) and dynamic (dynamic bending and low velocity impact) tests were already performed on the aluminum foam cored sandwiches with different types of outer skins by some of the authors. In the current investigation, the static three-point bending tests were carried out on the sandwiches with aluminum foam core and glass fiber reinforced polymer (GFRP) skins at different values of support span distances (L= 55, 70, 80, 125 mm) aiming the analyses of their flexural performance. The influence of the core thickness and the GFRP skin type was reported in terms of peak load, energy absorption capacity and energy efficiency. For this purpose, the skins with two different types of fabrics ([0°/90°] cross ply E-Glass Woven and [0°/90°] cross ply S-Glass Woven which have same thickness value of 1.5 mm) and the aluminum foam core with two different thicknesses (h=10 and 15 mm) were bonded with a commercial polyurethane based flexible adhesive in order to combine the composite sandwich panels. The GFRP skins fabricated via Vacuum Assisted Resin Transfer Molding (VARTM) technique used in the study can be easily bonded to the aluminum foam core and it is possible to configure the base materials (skin, adhesive and core), fiber angle orientation and number of layers for a specific application. The main results of the bending tests are: force-displacement curves, peak force values, absorbed energy, energy efficiency, collapse mechanisms and the effect of the support span length and core thickness. The results of the experimental study showed that the sandwich with the skins made of S-Glass Woven fabrics and with the thicker foam core presented higher mechanical values such as load carrying and energy absorption capacities. The increment of the support span distance generated the decrease of the mechanical values for each type of panels, as expected, because of the inverse proportion between the force and span length. The most common failure types of the sandwiches are debonding of the upper or lower skin and the core shear. The obtained results have particular importance for applications that require lightweight structures with a high capacity of energy dissipation, such as the transport industry (automotive, aerospace, shipbuilding and marine industry), where the problems of collision and crash have increased in the last years.

Keywords: aluminum foam, composite panel, flexure, transport application

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Authors: Nasim Abuali Galehdari, Venkat Mani, Ajit D. Kelkar

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Space Radiation has become one of the major factors in successful long duration space exploration. Exposure to space radiation not only can affect the health of astronauts but also can disrupt or damage materials and electronics. Hazards to materials include degradation of properties, such as, modulus, strength, or glass transition temperature. Electronics may experience single event effects, gate rupture, burnout of field effect transistors and noise. Presently aluminum is the major component in most of the space structures due to its lightweight and good structural properties. However, aluminum is ineffective at blocking space radiation. Therefore, most of the past research involved studying at polymers which contain large amounts of hydrogen. Again, these materials are not structural materials and would require large amounts of material to achieve the structural properties needed. One of the materials to alleviate this problem is polymeric composite materials, which has good structural properties and use polymers that contained large amounts of hydrogen. This paper presents steps involved in fabrication of multi-functional hybrid sandwich panels that can provide beneficial radiation shielding as well as structural strength. Multifunctional hybrid sandwich panels were manufactured using vacuum assisted resin transfer molding process and were subjected to radiation treatment. Study indicates that various nanoparticles including Boron Nano powder, Boron Carbide and Gadolinium nanoparticles can be successfully used to block the space radiation without sacrificing the structural integrity.

Keywords: multi-functional, polymer composites, radiation shielding, sandwich composites

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Authors: Saran Toure

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Complex shaped parts manufactured using out of autoclave prepreg vacuum bagging has a high quality finish. This is not only due to in the control of resin to fibre ratio in prepregs, but also to a reduction in fibre misalignment, slippage and stresses occurring within plies during compaction. In a bid to further reduce deformation modes and control failure modes, we carried experiments where, we introduced wetted fabrics within a prepreg plybook during compaction. Here are presented the results obtained from the vacuum bagging of a complex shaped part. The shape is that of a turbine fan blade with smooth curves all throughout ending with sharp edged angles. The quality of the final part made from this blade is compared to that of the same blade made from standard vacuum bagging process of prepregs, without introducing wetted fabrics.

Keywords: complex shaped part, prepregs, drapability, vacuum bagging

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Authors: Chil-Chyuan Kuo, Chen-Hsuan Tsai

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This study presents a cost-effective approach for rapid fabricating modeling platforms utilized in fused deposition modeling system. A small-batch production of modeling platforms about 20 pieces can be obtained economically through silicone rubber mold using vacuum casting without applying the plastic injection molding. The air venting systems is crucial for fabricating modeling platform using vacuum casting. Modeling platforms fabricated can be used for building rapid prototyping model after sandblasting. This study offers industrial value because it has both time-effectiveness and cost-effectiveness.

Keywords: vacuum casting, fused deposition modeling, modeling platform, sandblasting, surface roughness

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Authors: Wenbo Yu, Zihao Yuan, Zhipeng Guo, Shoumei Xiong

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Under different slow shot speeds in vacuum assisted high pressure die casting (VHPDC) process, plate-shaped specimens of hypereutectic A390 aluminum alloy were produced. According to the results, the vacuum pressure inside the die cavity increased linearly with the increasing slow shot speed at the beginning of mold filling. Meanwhile, it was found that the tensile properties of vacuum die castings were deteriorated by the porosity content. In addition, the average primary Si size varies between 14µm to 23µm, which has a binary functional relationship with the slow shot speeds. Due to the vacuum effect, the castings were treated by T6 heat treatment. After heat treatment, microstructural morphologies revealed that needle-shaped and thin-flaked eutectic Si particles became rounded while Al2Cu dissolved into α-Al matrix. For the as-received sample in-situ tensile test, microcracks firstly initiate at the primary Si particles and propagated along Al matrix with a transgranular fracture mode. In contrast, for the treated sample, the crack initiated at the Al2Cu particles and propagated along Al grain boundaries with an intergranular fracture mode. In-situ three bending test, microcracks firstly formed in the primary Si particles for both samples. Subsequently, the cracks between primary Si linked along Al grain boundaries in as received sample. In contrast, the cracks in primary Si linked through the solid lines in Al matrix. Furthermore, the fractography revealed that the fracture mechanism has evolved from brittle transgranular fracture to a fracture mode with many dimples after heat treatment.

Keywords: A390 aluminum, vacuum assisted high pressure die casting, heat treatment, mechanical properties

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Authors: Latha Krishnan, Andrew Cobley

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Epoxy resin is most widely used as matrices for composites of aerospace, automotive and electronic applications due to its outstanding mechanical properties. These properties are chiefly predetermined by the chemical structure of the prepolymer and type of hardener but can also be varied by the processing conditions such as prepolymer and hardener mixing, degassing and curing conditions. In this research, the effect of degassing on the curing behaviour and the void occurrence is experimentally evaluated for epoxy /anhydride resin system. The epoxy prepolymer was mixed with an anhydride hardener and accelerator in an appropriate quantity. In order to investigate the effect of degassing on the curing behaviour and void content of the resin, the uncured resin samples were prepared using three different methods: 1) no degassing 2) degassing on prepolymer and 3) degassing on mixed solution of prepolymer and hardener with an accelerator. The uncured resins were tested in differential scanning calorimeter (DSC) to observe the changes in curing behaviour of the above three resin samples by analysing factors such as gel temperature, peak cure temperature and heat of reaction/heat flow in curing. Additionally, the completely cured samples were tested in DSC to identify the changes in the glass transition temperature (Tg) between the three samples. In order to evaluate the effect of degassing on the void content and morphology changes in the cured epoxy resin, the fractured surfaces of cured epoxy resin were examined under the scanning electron microscope (SEM). Also, the changes in the mechanical properties of the cured resin were studied by three-point bending test. It was found that degassing at different stages of resin mixing had significant effects on properties such as glass transition temperature, the void content and void size of the epoxy/anhydride resin system. For example, degassing (vacuum applied on the mixed resin) has shown higher glass transition temperature (Tg) with lower void content.

Keywords: anhydride epoxy, curing behaviour, degassing, void occurrence

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Authors: Ali Ramezani

Abstract:

Balancing feeding system of plastic injection molding has overriding importance as it minimizes the process’s product defects such as weld line, shrinkage, sink marks and warpage. This article presents the difference between optimization of feeding system in identical multi-cavity molding and family molding using Moldflow Plastic Insight software. In this work, the effect of dimension, shape, position and type of gates and runners on the products quality was studied. The optimization was carried out by analyzing plastic injection molding process parameters, including melt temperature, mold temperature, cooling time, cooling temperature packing time and packing pressure. It was found that symmetrical feeding system is the most efficient shape for diminishing defects in identical multi-cavity molding. However, the same results were not concluded for family molding due to the differences between volume, mass, thickness and shape of cavities.

Keywords: balancing feeding system, family molding, multi-cavity, Moldflow, plastic injection

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Authors: Farid Arya, Trevor Hyde

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The development of vacuum glazing represents a significant advancement in the area of low heat loss glazing systems with the potential to substantially reduce building heating and cooling loads. Vacuum glazing consists of two or more glass panes hermetically sealed together around the edge with a vacuum gap between the panes. To avoid the glass panes from collapsing and touching each other under the influence of atmospheric pressure an array of support pillars is provided between the glass panes. A high level of thermal insulation is achieved by evacuating the spaces between the glass panes to a very low pressure which greatly reduces conduction and convection within the space; therefore heat transfer through this kind of glazing is significantly lower when compared with conventional insulating glazing. However, vacuum glazing is subject to inherent stresses due to atmospheric pressure and temperature differentials which can lead to fracture of the glass panes and failure of the edge seal. A flexible edge seal has been proposed to minimise the impact of these issues. In this paper, vacuum glazing system with rigid and flexible edge seals is theoretically studied and their advantages and disadvantages are discussed.

Keywords: flexible edge seal, stress, support pillar, vacuum glazing

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Authors: Gia Lam Le, Dennis T. Bergado, Thi Ngoc Truc Nguyen

Abstract:

This study focuses on behaviors of improved soft clay using prefabricated vertical drain (PVD) combined with vacuum and electro-osmotic preloading. Large-scale consolidations of reconstituted soft Bangkok clay were conducted for PVD improvement with vacuum (vacuum-PVD), and vacuum combined with heat (vacuum-thermo-PVD). The research revealed that vacuum-thermo-PVD gives high efficiency of the consolidation rate compared to the vacuum-PVD. In addition, the magnitude of settlement of the specimen improved by the vacuum-thermo-PVD is higher than the vacuum-PVD because the assistance of heat causes the collapse of the clay structure. Particularly, to reach 90% degree of consolidation, the thermal-vacuum-PVD reduced about 58% consolidation time compared to the vacuum-PVD. The increase in consolidation rate is resulted from the increase in horizontal coefficient of consolidation, Ch, the reduction of the smear effect expressed by the ratio of the horizontal hydraulic conductivity in the undisturbed zone, kh, and the horizontal hydraulic conductivity in the smeared zone, ks. Furthermore, the shear strength, Su, increased about 100% when compared using the vacuum-thermal-PVD to the vacuum PVD. In addition, numerical simulations gave reasonable results compared to the laboratory data.

Keywords: PVD improvement, vacuum preloading, prefabricated vertical drain, thermal PVD

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Authors: Latha Krishnan, Andrew Cobley

Abstract:

Epoxy resin is most widely used as matrices for composites of aerospace, automotive and electronic applications due to its outstanding mechanical properties. These properties are chiefly predetermined by the chemical structure of the prepolymer and type of hardener but can also be varied by the processing conditions such as prepolymer and hardener mixing, degassing and curing conditions. In this research, the effect of degassing on the curing behaviour and the void occurrence is experimentally evaluated for epoxy /anhydride resin system. The epoxy prepolymer was mixed with an anhydride hardener and accelerator in an appropriate quantity. In order to investigate the effect of degassing on the curing behaviour and void content of the resin, the uncured resin samples were prepared using three different methods: 1) no degassing 2) degassing on prepolymer and 3) degassing on mixed solution of prepolymer and hardener with an accelerator. The uncured resins were tested in differential scanning calorimeter (DSC) to observe the changes in curing behaviour of the above three resin samples by analysing factors such as gel temperature, peak cure temperature and heat of reaction/heat flow in curing. Additionally, the completely cured samples were tested in DSC to identify the changes in the glass transition temperature (Tg) between the three samples. In order to evaluate the effect of degassing on the void content and morphology changes in the cured epoxy resin, the fractured surfaces of cured epoxy resin were examined under the scanning electron microscope (SEM). In addition, the amount of void, void geometry and void fraction were also investigated using an optical microscope and image J software (image analysis software). It was found that degassing at different stages of resin mixing had significant effects on properties such as glass transition temperature, the void content and void size of the epoxy/anhydride resin system. For example, degassing (vacuum applied on the mixed resin) has shown higher glass transition temperature (Tg) with lower void content.

Keywords: anhydride epoxy, curing behaviour, degassing, void occurrence

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Authors: R. A. C. H. Seneviratne, M. Gunawardana, R. P. N. P. Rajapakse

Abstract:

To address the micronutrient deficiencies in the Asian region, the World Food Program in its current mandate highlights the requirement of employing efficient fortification of micronutrients in rice, under the program 'Scaling-up Rice Fortification in Asia'. The current industrial methods of rice fortification with micronutrients are not promising due to poor permeation or retention of fortificants. This study was carried out to develop a method to improve fortification of micronutrients in rice by removing the air barriers for diffusing micronutrients through the husk. For the purpose, soaking stage of paddy was coupled with vacuum (- 0.6 bar) for different time periods. Both long and short grain varieties of paddy (BG 352 and BG 358, respectively) initially tested for water uptake during hot soaking (70 °C) under vacuum (28.5 and 26.15%, respectively) were significantly (P < 0.05) higher than that of non-vacuum conditions (25.24 and 25.45% respectively), exhibiting the effectiveness of water diffusion into the rice grains through the cleared pores under negative pressure. To fortify the selected micronutrients (iron and zinc), paddy was vacuum-soaked in Fe2+ or Zn2+ solutions (500 ppm) separately for one hour, and continued soaking for another 3.5 h without vacuum. Significantly (P<0.05) higher amounts of Fe2+ and Zn2+ were observed throughout the soaking period, in both short and long grain varieties of rice compared to rice treated without vacuum. To achieve the recommended limits of World Food Program standards for fortified iron (40-48 mg/kg) and zinc (60-72 mg/kg) in rice, soaking was done with different concentrations of Fe2+ or Zn2+ for varying time periods. For both iron and zinc fortifications, hot soaking (70 °C) in 400 ppm solutions under vacuum (- 0.6 bar) during the first hour followed by 2.5 h under atmospheric pressure exhibited the optimum fortification (Fe2+: 46.59±0.37 ppm and Zn2+: 67.24±1.36 ppm) with a greater significance (P < 0.05) compared to the controls (Fe2+: 38.84±0.62 ppm and Zn2+: 52.55±0.55 ppm). This finding was further confirmed by the XRF images, clearly showing a greater fixation of Fe2+ and Zn2+ in the rice grains under vacuum treatment. Moreover, there were no significant (P>0.05) differences among both Fe2+ and Zn2+ contents in fortified rice even after polishing and washing, confirming their greater retention. A seven point hedonic scale showed that the overall acceptability for both iron and zinc fortified rice were significantly (P < 0.05) higher than the parboiled rice without fortificants. With all the drawbacks eliminated, per kilogram cost will be less than US$ 1 for both iron and zinc fortified rice. The new method of rice fortification studied and developed in this research, can be claimed as the best method in comparison to other rice fortification methods currently deployed.

Keywords: fortification, vacuum assisted diffusion, micronutrients, parboiling

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Authors: Mathieu Imbert, Sebastien Comas-Cardona, Emmanuelle Abisset-Chavanne, David Prono

Abstract:

Short cycle time Resin Transfer Molding (RTM) applications appear to be of great interest for the mass production of automotive or aeronautical lightweight structural parts. During the RTM process, the two components of a resin are mixed on-line and injected into the cavity of a mold where a fibrous preform has been placed. Injection and polymerization occur simultaneously in the preform inducing evolutions of temperature, degree of cure and viscosity that furthermore affect flow and curing. In order to adjust the processing conditions to reduce the cycle time, it is, therefore, essential to understand and quantify the physical mechanisms occurring in the part during injection. In a previous study, a dual-scale simulation tool has been developed to help determining the optimum injection parameters. This tool allows tracking finely the repartition of the resin and the evolution of its properties during reactive injections with on-line mixing. Tows and channels of the fibrous material are considered separately to deal with the consequences of the dual-scale morphology of the continuous fiber textiles. The simulation tool reproduces the unsaturated area at the flow front, generated by the tow/channel difference of permeability. Resin “storage” in the tows after saturation is also taken into account as it may significantly affect the repartition and evolution of the temperature, degree of cure and viscosity in the part during reactive injections. The aim of the current study is, thanks to experiments, to understand and quantify the “storage” evolution in the tows to adjust and validate the numerical tool. The presented study is based on four experimental repeats conducted on three different types of textiles: a unidirectional Non Crimp Fabric (NCF), a triaxial NCF and a satin weave. Model fluids, dyes and image analysis, are used to study quantitatively, the resin flow in the saturated area of the samples. Also, textiles characteristics affecting the resin “storage” evolution in the tows are analyzed. Finally, fully coupled on-line mixing reactive injections are conducted to validate the numerical model.

Keywords: experimental, on-line mixing, high-speed RTM process, dual-scale flow

Procedia PDF Downloads 165