Process Induced Defects in Liquid Molding Processes of Composites

Liquid Composite Molding (LCM) processes are cost efficient manufacturing alternatives to traditional autoclave technology for producing near-net shape structural composite parts. However, process induced defects often limit wider usage of LCM in structural applications. Thorough knowledge of these defects, as well as their formation mechanisms and prevention techniques is essential in developing improved LCM processes. In this article, process induced defects in liquid molding processes of composites, categorized into preform, flow induced and cure induced defects, are reviewed. Preform defects are further presented as fiber misalignment and fiber undulation (waviness and wrinkling). The respective causes, detrimental effects, and possible prevention methods of these defects are presented. Thereafter, flow induced defects are classified as voids and dry spots. Dry spot formation mechanisms in LCM processes and available prevention techniques are summarized. In addition, void formation mechanisms, adverse effects on composite properties, and removal techniques are presented. Cure induced defects include microcracks, void growth and geometrical distortions (warpage and spring-in). Each of these defects are discussed along with their underlying causes as well as their control and reduction schemes.Ye

ASME IMECE2003 -43837 FORMATION OF MICROSCOPIC VOIDS IN RESIN TRANSFER MOLDED COMPOSITES

ABSTRACT Performance of composite materials usually suffers from process-induced defects such as dry spots or microscopic voids. While effects of void content in molded composites have been studied extensively, knowledge of void morphology and spatial distribution of voids in composites manufactured by resin transfer molding (RTM) remains limited. In this study, through-the-thickness void distribution for a diskshaped, E-glass/epoxy composite part manufactured by resin transfer molding is investigated. Microscopic image analysis is conducted through-the-thickness of a radial sample obtained from the molded composite disk. Voids are primarily found to concentrate within or adjacent to the fiber preforms. More than 93% of the voids are observed within the preform or in a so-called transition zone, next to a fibrous region. In addition, void content was found to fluctuate through-the-thickness of the composite. Variation up to 17% of the average void content of 2.15% is observed through-the-thicknesses of the eight layers studied. Microscopic analysis revealed that average size of voids near the mold surfaces is slightly larger than those located at the interior of the composite. In addition, average size of voids that are located within the fiber preform is observed to be smaller than those located in other regions of the composite. Finally, proximity to the surface is found to have no apparent effect on shape of voids within the composite

Prediction of moisture saturation levels for vinylester composite laminates : a data-driven approach for predicting the behavior of composite materials

Presented at the 34th International Conference of the Polymer Processing Society, May 24, 2018.This paper introduces a comprehensive, data-driven method to predict the properties of composite materials, such as thermo-mechanical properties, moisture saturation level, durability, or other such important behavior. The approach is based on applying data mining techniques to the collective knowledge in the materials field. In this article, first, a comprehensive database is compiled from published research articles. Second, the Random Forests algorithm is used to build a predictive model that explains the investigated material response based on a wide variety of material and process variables (of different data types). This advanced statistical learning approach has the potential to drastically enhance the design of composite materials by selecting appropriate constituents and process parameters in order to optimize the response for a specific application. This method is demonstrated by predicting the moisture saturation level for vinylester-based composite laminates. Using 90% of the available published data available as the training dataset, the Random Forests algorithm is used to develop a regression model for the moisture saturation level. Variables considered by the model include the manufacturing process, the fiber type and architecture, the fiber and void contents, the matrix filler type and content, as well as the conditioning environment and temperature. On this training data, the model proved to be a good fit with a prediction accuracy of R^2(training)=94.96%. When used to predict the moisture saturation level for the remaining unseen 10% of the compiled data, the model exhibited a prediction accuracy of R^2(test)=85.28%. Furthermore, the Random Forests model allows the assessment of the impact of the different variables on the moisture saturation level. The fiber type is found to be the most important determinant on the moisture saturation level in vinylester composite laminates.YesPeer reviewed for the proceedings of the 34t

Accurate characterization of moisture absorption in polymeric materials

The importance of using the exact solution of the hindered diffusion model is demonstrated on experimental data from a nanoclay/epoxy composite.Ye

Modeling and Experimental Validation of Anomalous Moisture Absorption of Micro and Nanocomposite Laminates

Susceptibility of polymeric composites to moisture has been well known for several decades. Most high performance epoxy or bismaleimide (BMI) resins and their fiber-reinforced composites may absorb up to 5 wt% moisture which could lead to 10-30% reduction in various mechanical properties, including flexural strength, stiffness, impact resistance, and interlaminar shear strength (ILSS). In particular, fiber-matrix interface and process-induced defects such as microvoids often act as moisture storage sites, thus increasing the maximum intake level. It has been common practice to use a Fickian model to characterize the diffusion of moisture into polymeric composites. However, in several high-performance and mission critical applications, more sophisticated models accounting for the edge effects, anisotropy of absorption, molecular interactions, and interfacial storage are required to fully describe the long- and short-term moisture absorption dynamics. In this article, a model that combines the classical Fickian behavior and diffusion hindrance due to molecular bonding is used to explain anomalous absorption. The hindered diffusion model (HDM) is shown to predict both short-term Fickian and long-term anomalous, non-Fickian absorption behavior often observed in structural composites. The total amount of absorption is shown to be the sum of bound and unbound liquids, which are coupled through a differential diffusion and a temporal storage model. The accuracy of the model predictions is discussed by comparing the model predictions with the experimentally measured mass gain of graphite/epoxy laminates and clay/epoxy nanocomposites. It is shown that the anomalous moisture absorption dynamics observed in these laminates can be accurately predicted by the hindered diffusion model.YesPolymer Processing Society Asia/Australia Conference PPS-2016, October 11-14, 2016, Chengdu, Chin

Effect of Preform Thickness and Volume Fraction on Injection Pressure and Mechanical Properties of Resin Transfer Molded Composites

An experimental study is performed to characterize the effect of the thickness of random preforms on injection pressure and mechanical properties of resin transfer molded (RTM) parts. Center-gated, disk-shaped parts are molded using two different chopped-strand glass fiber preforms. Both preforms have random microstructure but different planar densities (i.e., different uncompressed layer thicknesses). Tensile strength, short-beam shear strength, and elastic modulus are measured for parts molded with each preform type at three different fiber volume fractions of 6.84, 15.55, and 24.83%. Although mechanical properties are found to increase linearly with volume fraction, significant difference is not observed between disks containing thick and thin mats at equivalent fiber volume fraction.Yeshttps://us.sagepub.com/en-us/nam/manuscript-submission-guideline

Performance of Glass Woven Fabric Composites with Admicellar-Coated Thin Elastomeric Interphase

Adequate stress transfer between the inorganic reinforcement and surrounding polymeric matrix is essential for achieving enhanced structural integrity and extended lifetime performance of fiber-reinforced composites. The insertion of an elastomeric interlayer helps increase the stress-transfer capabilities across the fiber/matrix interface and considerably reduces crack initiation phenomena at the fiber ends. In this study, admicellar polymerization is used to modify the fiber/matrix interface in glass woven fabric composites by forming thickness-controlled poly(styrene-co-isoprene) coatings. These admicellar interphases have distinct characteristics (e.g., topology and surface coverage) depending on the surfactant/monomer (S/M) ratios used during the polymerization reaction. Overall, the admicellar coatings have a positive effect on the mechanical response of resin transfer molded (RTM), E-glass/epoxy parts. For instance, ultimate tensile strength (UTS) of composites with admicellar sizings improved 50 to 55% over the control desized samples. Interlaminar shear strength (ILSS) also showed increases ranging from 18 to 38% over the same control group. Interestingly, the flexural properties of these composites proved sensitive to the type of interphase formed for various admicellar polymerization conditions. Higher surface coverage and film connectedness in admicellar polymeric sizings are observed to enhance stress transfer at the interfacial region.Ye

Manufacturing silk/epoxy composite laminates : challenges and opportunities

Presented at the 34th International Conference of the Polymer Processing Society, May 24, 2018.Application of natural fibers in polymer composites has been gaining popularity in several industries pursuing environmentally friendly products. Among the natural fibers with proven potential applications, silk fibers have recently received considerable attention from researchers. Silk fibers provide higher mechanical properties compared to other commonly used natural fibers such as sisal, jute, and hemp. Silk may also exhibit comparable specific mechanical properties to glass fibers. However, silk composite laminates are rarely used in commercial products due to a number of fabrication challenges. This paper investigates such challenges for silk/epoxy laminates, especially issues related to manufacturing and preform architecture. First, challenges arising from preform architecture (i.e., random and woven preforms) are presented. Unlike glass fibers for which random mats are easier to manipulate, handling random silk preform proves to be more challenging, particularly compared to woven silk fabrics. The random silk/epoxy laminates show higher thickness variation and lower compaction, yielding lower fiber content. Second, fabrication of laminates by vacuum bag/wet lay-up and vacuum assisted resin transfer molding (VARTM) processes are presented. VARTM is found to be more appropriate for silk/epoxy laminate fabrication, as it allows a uniform impregnation of the silk preform, yielding higher part quality and limited void formation. Moreover, applying 0.21 MPa (30 psi) external pressure to the VARTM laminates allows to increase the fiber content of both random and woven silk/epoxy laminates from ~17 and ~30% to ~21 and ~33%, respectively. In contrast, wetting of silk preform during wet lay-up process, which is operator dependent, is difficult to achieve; and the produced laminates have high void content. Furthermore, SEM images show a weak silk/epoxy adhesion in laminates fabricated without external pressure. Finally, the mechanical performance of these laminates is assessed. The woven silk/epoxy laminates fabricated by pressurized VARTM exhibits the highest improvement in the specific flexural strength and modulus over pristine epoxy with 30 and 65% increase, respectively.YesPeer reviewed for the Proceedings of the 34th International Conference of the Polymer Processing Society, Taipei, Taiwan, May 21st-25th 2018

Effect of Nanoclay Content on Void Morphology in Resin Transfer Molded Composites

Effects of nanoclay content on morphology and spatial distribution of voids in resin transfer molded nanoclay/E-glass/epoxy composite disks are investigated. Closite®25A nanoclay loads of 2, 5, and 10wt% are mixed by sonication with a low-viscosity epoxy resin prior to filling the mold cavity containing 13.6% E-glass preform by volume. A disk without nanoclay is also molded. Once the molded composites are cured, voids on radial composite samples are evaluated via microscopic image analysis. The addition of nanoclay is found to result in a significant increase in the apparent viscosity of the clay-epoxy mixture, thus increasing the molding pressure. Void occurrence is observed to increase considerably with increasing nanoclay content, from 2.1% in the composite without nanoclay to 5.1 and 8.3% in the composites molded with 5 and 10wt% nanoclay, respectively. However, the composite with 2wt% nanoclay yields the lowest void content of 0.7%. Voids are observed to be, in average, smaller after the addition of nanoclay at all nanoclay concentrations. Presence of nanoclay in the impregnating resin induces at least 60% reduction in voids located inside fiber tows, which are trapped by the fluid front motion during impregnation. Irregularly shaped voids are also observed to decrease with increasing nanoclay content. A nonuniform void content and morphology is observed radially, which seems to be affected by the flow kinematics as well as possible breakdown and filtration of clay clusters.Yeshttps://us.sagepub.com/en-us/nam/manuscript-submission-guideline

Filtration and Breakdown of Clay Clusters during Resin Transfer Molding of Nanoclay/Glass/Epoxy Composites

Dispersion of nanoclay clusters during resin transfer molding of nanoclay/glass/epoxy disks is investigated. In addition to a center-gated disk containing only 14% glass fibers, three nanocomposite disks are fabricated with the addition of 2, 5 or 10 wt% Cloisite® 25A nanoclay. The spatial distribution of nanoclay clusters along the radial axis of the nanocomposite disks are characterized at two length scales. Clusters larger than 1.5 μm are characterized by performing image analysis on the SEM micrographs whereas smaller nanoclay clusters are identified by wavelength dispersive spectrometry. Results obtained from image analysis indicate that nanoclay clusters are filtered out by as much as 50% in the flow direction by the glass fiber preforms. In addition, increasing nanoclay content led to higher filtration, suggesting that cluster formation is more prominent at higher nanoclay loadings. Cluster size distribution analyses revealed that the outer edges of the disks, on average, contain finer nanoclay particles. For instance, the outer edge of the nanocomposite with 2% clay contains 22% more small nanoclay clusters compared to center of the disk. Glass transition temperature, Tg, of four specimens obtained from each molded disks is characterized under oscillatory shear. Glass transition temperature of the samples are shown to increase with the nanoclay content, yielding a 40% higher Tg at 10% nanoclay loading compared to glass/epoxy composite without clay. Increasing glass transition temperature with increasing nanoclay content may be an indication of intercalation of nanoclay within the epoxy matrix.Yeshttps://us.sagepub.com/en-us/nam/manuscript-submission-guideline