Search Results (66)

By embedding optical fiber sensors into fiber preforms and utilizing liquid molding processes such as resin transfer molding (RTM), intelligent composite materials with self-sensing capabilities can be fabricated. In the liquid molding process of these intelligent composites, the quality of the final product is highly dependent on the resin flow and impregnation effects. The embedding of optical fibers can affect the microscopic flow and impregnation behavior of the resin; therefore, it is necessary to investigate the specific impact of optical fiber embedding on the resin flow and impregnation of fiber bundles. Due to the difficulty of directly observing this process at the microscopic scale through experiments, numerical simulation has become a key method for studying this issue. This paper focuses on the resin micro-flow in RTM processes for intelligent composites with embedded optical fibers. Firstly, a steady-state analysis of the resin flow and impregnation process was conducted using COMSOL 6.0 obtaining the velocity and pressure field distribution characteristics under different optical fiber embedding conditions. Secondly, the dynamic process of resin flow and impregnation of fiber bundles at the microscopic scale was simulated using Fluent 2022R2. This study comprehensively analyzes the impact of different optical fiber embedding configurations on resin flow and impregnation characteristics, determining the impregnation time and porosity after impregnation under different optical fiber embedding scenarios. Additionally, this study reveals the mechanisms of pore formation and their distribution patterns. The research findings provide important theoretical guidance for optimizing the RTM molding process parameters for intelligent composite materials. Full article

Resin Transfer Molding (RTM) is a widely used composite manufacturing process where liquid resin is injected into a closed mold filled with a fibrous preform. By applying this process, large pieces with complex shapes can be produced on an industrial scale, presenting excellent properties and quality. A true physical phenomenon occurring in the RTM process, especially when using vegetable fibers, is related to the absorption of resin by the fiber during the infiltration process. The real effect is related to the slowdown in the advance of the fluid flow front, increasing the mold filling time. This phenomenon is little explored in the literature, especially for non-isothermal conditions. In this sense, this paper does a numerical study of the liquid injection process in a closed and heated mold. The proposed mathematical modeling considers the radial, three-dimensional, and transient flow, variable injection pressure, and fluid viscosity, including the effect of liquid fluid absorption by the reinforcement (fiber). Simulations were carried out using Computational Fluid Dynamic tools. The numerical results of the filling time were compared with experimental results, and a good approximation was obtained. Further, the pressure, temperature, velocity, and volumetric fraction fields, as well as the transient history of the fluid front position and injection fluid volumetric flow rate, are presented and analyzed. Full article

The agricultural sector faces growing pressure to enhance productivity and sustainability, prompting innovation in machinery design. Traditional materials such as steel still dominate but are a cause of increased weight, soil compaction, increased fuel consumption, and corrosion. Composite materials—and, more specifically, fiber-reinforced polymers (FRPs)—offer appealing alternatives due to their high specific strength and stiffness, corrosion resistance, and design flexibility. Meanwhile, increasing environmental awareness has triggered interest in biocomposites, which contain natural fibers (e.g., flax, hemp, straw) and/or bio-based resins (e.g., PLA, biopolyesters), aligned with circular economy principles. This review offers a comprehensive overview of synthetic composites and biocomposites for agricultural machinery and equipment (AME). It briefly presents their fundamental constituents—fibers, matrices, and fillers—and recapitulates relevant mechanical and environmental properties. Key manufacturing processes such as hand lay-up, compression molding, resin transfer molding (RTM), pultrusion, and injection molding are discussed in terms of their applicability, benefits, and limits for the manufacture of AME. Current applications in tractors, sprayers, harvesters, and planters are covered in the article, with advantages such as lightweighting, corrosion resistance, flexibility and sustainability. Challenges are also reviewed, including the cost, repairability of damage, and end-of-life (EoL) issues for composites and the moisture sensitivity, performance variation, and standardization for biocomposites. Finally, principal research needs are outlined, including material development, long-term performance testing, sustainable and scalable production, recycling, and the development of industry-specific standards. This synthesis is a practical guide for researchers, engineers, and manufacturers who want to introduce innovative material solutions for more efficient, longer lasting, and more sustainable agricultural machinery. Full article

Crosslinked phenolic resin was prepared using hexamethylenetetramine (HMTA) as a crosslinking agent in hydrochloric acid solution. The ablation-heat-resistant material was prepared by a pressure-assisted RTM (resin transfer molding) process with reinforcing material (quartz fibre 2.5D needle-punched fabric/satin fibre cloth/fibre mesh tire) and matrix (crosslinked phenolic resin). The thermal stability of the cured product was studied by a thermogravimetric analyser (TG and DTG). The mechanical properties, heat resistance, and ablation properties of the composites were tested. The ablation morphology, element analysis, and phase structure of the composites were analysed by scanning electron microscopy (SEM), energy dispersive spectrometry (EDS), and X-ray diffraction (XRD), respectively. The results show that the phenolic resin has a lower initial viscosity and a longer pot life at 80 °C, and a higher carbon residue rate (70.18%). The tensile strength of the composites is close to 40 MPa, the tensile modulus is higher than 1.35 GPa, the compression modulus is higher than 10 MPa, and the elongation at break is higher than 1.55%. SiO₂, SiC, and ZrO₂ ceramic phases were formed after ablation, which effectively improved the ablation performance of the composites. Full article

Recycling carbon-fiber-reinforced plastics (CFRPs) is crucial for sustainable material utilization, particularly in aerospace applications, where large quantities of prepreg waste are generated. This study investigated the mechanical properties of highly oriented recycled CFRP (rCFRP) molded using vacuum-assisted resin transfer molding (VaRTM), wet-layup, and traditional RTM methods. Recycled carbon fibers (rCFs) obtained via solvolysis and pyrolysis were processed into nonwoven preforms to ensure fiber alignment through carding. The influence of molding methods, fiber recycling techniques, and fiber orientation on mechanical performance was examined through tensile tests, fiber volume fraction (Vf) analysis, and scanning electron microscopy observations. The results indicated that the solvolysis-recycled rCF exhibited superior interfacial adhesion with the resin, leading to a higher tensile strength and stiffness, particularly in the RTM process, where a high Vf was achieved. Wet-layup molding effectively reduced the void content owing to autoclave curing, maintaining stable properties even with pyrolyzed rCF. VaRTM, while enabling vacuum-assisted resin infusion, exhibited a higher void content, limiting improvements in mechanical performance. This study highlights that tailoring the molding method according to the desired performance, such as increasing stiffness potential by enhancing Vf in RTM or improving tensile strength by improving fiber–matrix adhesion in wet-layup molding, is critical for optimizing rCFRP properties, providing important insights into sustainable CFRP recycling and high-performance material design. Full article

Resin transfer molding (RTM) is a key process for manufacturing high-performance fiber-reinforced composites, in which resin infiltration dynamics play a critical role in process efficiency and defect minimization. This study presents a numerical and experimental analysis of resin flow in biaxial noncrimp carbon fiber reinforcement using FormuLITE 2500A/2401B epoxy. A model based on Darcy’s law and resin sorption effects was developed to investigate the influence of injection pressure (15–25 kPa), permeability (350 × 10⁻¹² m² to 0.035 × 10⁻¹² m²), porosity (0.78–0.58), viscosity (0.28–0.48 Pa·s), and injection radius (0.001–0.003 m) on flow-front progression. The results show that a higher injection pressure increased the infiltration depth by 30% at 250 s, while a 100× reduction in permeability reduced infiltration by 75%. The increased viscosity slowed the resin flow by ~18%, and the lower porosity reduced the flow-front progression by 15%. The experimental validation demonstrated a relative error of <5% between the numerical predictions and the measured data. This study provides critical insights into RTM process optimization for uniform fiber impregnation and defect minimization. Full article

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. Full article

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. Full article

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. Full article

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. Full article

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%. Full article

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. Full article

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. Full article

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. Full article

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. Full article