Abstract
The optimization of the mechanical properties of composite materials has been a challenge since these materials were first used, especially in aeronautics. Reduced energy consumption, safety and reliability are mandatory to achieve a sustainable use of composite materials. The mechanical properties of composites are closely related to the amount of defects in the materials. Voids are known as one of the most important defect sources in resin film infusion (RFI)-manufactured composites. Minimizing the defect content leads to maximized mechanical properties and lightweight design. In this paper, a novel methodology based on computer vision is applied to control the impregnation velocity, reduce the void content and enhance the impact properties. Optimized drop-impact properties were found once the impregnation velocity was analyzed and optimized. Its application in both conventional and stitching-reinforced composites concludes with an improvement in the damage threshold load, peak force and damaged area. Although stitching tends to generate additional voids and reduces in-plane properties, the reduction in the damaged area means a positive balance in the mechanical properties. At the same time, the novel methodology provides the RFI process with a noticeable level of automation and control. Consequently, the industrial interest and the range of applications of this process are enhanced.
Highlights
Composite materials are widely used in industries such as transportation and energy, where high performance in mechanical properties is often required
Liquid composite manufacturing (LCM) techniques are characterized by using the infusion or injection of the resin into a mold once the initial preformed dried fibers are placed inside
A novel manufacturing methodology was applied to optimize the impact properties of stitched and unstitched laminates in the resin film infusion (RFI) process. It was based on the control of the impregnation velocity which can reduce the void content
Summary
Composite materials are widely used in industries such as transportation and energy, where high performance in mechanical properties is often required. Depending on the production rate and part complexity, different types of processes are available to manufacture composite materials. Liquid composite manufacturing (LCM) techniques are characterized by using the infusion or injection of the resin into a mold once the initial preformed dried fibers are placed inside. The performance of the main processes in this group—including the resin transfer molding (RTM), RTM Light and resin film infusion (RFI)—is strongly dependent on how the dry fibers are impregnated. Increasing the level of component integration and process automation is another of the current objectives of the composite materials’ industry, so as to reduce the manufacturing, handling and assembly times [2]
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