Harry J. Barraza

Effect of injection rate and post-fill cure pressure on properties of resin transfer molded disks

The effects of flow rate andpost-fill cure pressure, i.e., packing pressure, on the mechanical properties of resin transfer molded disks are experimentally investigated. An experimental molding setup is constructed to fabricate fiber-reinforced, center-gated, disk-shaped composite parts. Disks are molded at different flow rates and packing pressures in order to observe the effects of these parameters on the mechanical properties andvoidcontent of the final parts. Specimens are cut from three different locations in the molded disks for testing. Specimens from the first two locations are tensile testedto obtain strength and stiffness properties, and the third location is usedfor microscopic analysis to determine void content and void properties. Increased injection rate is found to reduce both the strength and stiffness of the molded parts due to more voids induced by the faster moving fluidfront. Packing pressure is also foundto have a significant effect on specimen properties. At higher packing pressures fewer voids and improved strength andstiffness are observed. Mechanical properties are correlatedwith total void fraction for disks molded at different packing pressures. Exponential decrease in both tensile strength andelastic modulus is observedwith increasing voidfraction. Doubling the voidvolume fraction from 0.35 to 0.72% results in a 15% decrease in strength and a 14% decrease in stiffness. The results demonstrate that selection of suitable injection rate and addition of packing pressure to resin transfer molding (RTM) process can improve mechanical properties of molded parts considerably.

Porosity Reduction in the High-Speed Processing of Glass-Fiber Composites by Resin Transfer Molding (RTM)

High-speed processing is essential to achieve lower production cost in the fabrication of fiber-reinforced composites with the current liquid molding practices. A major consequence of increasing the resin injection velocity is the formation of defects such as voids and dry regions that decrease the load-bearing capability of the composite. Void formation mechanisms and analytical predictions of the detrimental effect of porosity on the structural integrity of molded parts have been studied extensively. In contrast, knowledge of void removal strategies is very limited. In this investigation, various postfill pressure levels were applied to disk-shaped random-mat glass/epoxy parts molded at high volumetric flow rates as a method to reduce their voidage content. Quantitative image analysis over cross-sections cut from these composites revealed that significant changes in porosity concentration take place with the postfill pressure. For instance, overall void content dropped more than 70% with the application of a postfill pressure as low as 300 kPa. Other important void morphometry characteristics such as void shape, size, and spatial distribution could also be manipulated by this method. As the packing pressure increases, large voids gradually disappear, and at the same time, the small circular voids are mobilized towards radial locations near the vents. In addition to this spatial voidage gradient in the radial direction, voidage gradient also exists through the specimen thickness. It seems that higher front velocities promote the appearance of secondary flow phenomena inside the mold cavity (e.g. microfountain flow), which may explain why more voids tend to concentrate at the surface of the specimen irrespective of the postfill pressure level reached inside the mold.

Moisture absorption and wet-adhesion properties of resin transfer molded (RTM) composites containing elastomer-coated glass fibers

Transient water sorption studies were carried out at constant temperature (45 °C) to assess the hydrolytic stability and wet-adhesion properties of glass fiber/epoxy composites having different sizings. Lower effective diffusivity values correlated with improved overall mechanical performance in relation to the control (unsized) samples, and revealed the importance of changing the surface energy characteristics of glass fibers by using distinctively hydrophobic pure polymers. Admicellar polystyrene and styrene-isoprene coatings formed over the inorganic reinforcement appear to create an interface with much higher resistance to moisture attack than the organosilane/matrix interface in composites with commercial sizing. This fact was corroborated by comparing their effectiveness in property retention, which showed the mechanical property (e.g. ultimate tensile strength, stiffness and interlaminar shear strength) increased with respect to the uncoated composites in the dry state as well as after water saturation. Poor wet-adhesion properties of commercial sizings in humid conditions could perhaps be attributed to higher contents of inert material present in these coatings. Fractography analysis was consistent with the previous observations regarding catastrophic failure in composites without coating, and suggested that interfacial debonding, extensive fiber pullout and matrix crazing were the major contributors to the overall failure mechanism. Failed surfaces of both commercial and elastomer-coated composites also showed areas with fiber pullout, but in this case, matrix residues remained on the fiber surfaces, yielding a much rougher appearance. Good fiber-matrix adhesion, particularly in admicellar-coated composites, was also revealed by the presence of hackles and more tortuous failure paths.

Elastomeric sizings for glass fibers and their role in fiber wetting and adhesion in resin transfer molded composites

Mold fill velocities of 0.067 cm3/s and 2.66 cm3/s were used to impregnate glass fiber preforms with different architectures and sizing types in two force-controlled resin transfer molding (RTM) fixtures. The fabrication of disk-shaped parts at high molding speed and high post-cure fill pressure was proven successful in reducing the amount of flow-induced defects for reinforcements with a random nonlayered structure. Investigations on the effect of fiber/matrix interface modification with controlled-thickness elastomeric films obtained by the admicellar polymerization technique were carried out to assess the structural integrity levels attained with these less expensive polymeric sizings. In particular, parts reinforced with fibers coated with a thin film of styrene-isoprene copolymer performed significantly better than the uncoated control samples in the tensile and flexural tests. For the same sizing type, the interlaminar shear strength was more than 30% higher than the desized composite and compared statistically to the adhesion level exhibited by commercially sized reinforcements. Greater data scatter and poorer adhesion performance was observed for those composites containing fibers with a thin polystyrene coat. We infer that beneficial effects of a nanometer-thick elastomer interlayer are more evident when extensive cooperative segmental motions take place, that is, when the surface glass transition temperature of the sizing is far below the room temperature. These results have implications for composite manufacture applications involving tailored interfaces with flexible sizings.

Performance of glass woven fabric composites with admicellar-coated thin elastomeric interphase

Abstract 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 ratios used during the polymerization reaction. Overall, the admicellar coatings have a positive effect on the mechanical response of resin transfer molded, E-glass/epoxy parts. For instance, ultimate tensile strength of composites with admicellar sizings improved 50–55% over the control-desized samples. Interlaminar shear strength 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.