Resin Transfer Research Articles

Influence of carbon nanotubes on the absorption performance and mechanical behavior of basalt fiber composite materials

AbstractBasalt fibers (BF) are widely used in shipbuilding due to their excellent corrosion resistance. However, basalt fibers do not possess good electromagnetic wave absorption properties, failing to meet the stealth performance requirements of ships. Therefore, this study focuses on basalt fiber composite materials, modifying the matrix by adding different amounts of carbon nanotubes (CNTs). Carbon nanotube‐basalt fiber‐epoxy resin absorptive composite materials are prepared using Vacuum Assisted Resin Transfer Molding (VARTM) technique to investigate the influence of CNT content on the materials. Samples with added CNTs can effectively absorb electromagnetic waves in the low‐frequency range, reducing surface reflectivity. In the high‐frequency range, the impedance matching value of the samples initially increases slowly. When the CNT content reaches 1.5 wt%, at a thickness of 2.5 mm and a frequency of 9.6 GHz, the minimum reflection loss of the sample is −14.40 dB, with an effective absorption bandwidth of 0.7 GHz. Also, CNTs can enhance the mechanical properties of composite materials. With increasing CNT content, both the bending strength and tensile strength of the composite materials are improved. When the CNT content reaches 1.5 wt%, the average tensile fracture strength of the material increases by 21%, and the bending strength increases by 9%.Highlights Enhanced low‐frequency electromagnetic wave absorption from CNTs and reduced polarization. Improved impedance matching and attenuation at high frequencies with CNTs. Significant enhancement in flexural and tensile strength due to CNTs and basalt fibers.

In‐situ fabrication of poly‐l‐lactide & its application as a glass fiber polymer composites using resin transfer molding

In‐situ fabrication of poly‐l‐lactide & its application as a glass fiber polymer composites using resin transfer molding

On the Fabrication Processes of Structural Supercapacitors by Resin Transfer Molding and Vacuum-Assisted Resin Transfer Molding

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.

Quasi-static punch shear behavior of glass/epoxy composite: Experimental and numerical study in artificial seawater environment

Enhancing the understanding of how fiber-reinforced polymer composites respond to high-speed impacts is crucial, particularly in comparison to Quasi-Static Punch Shear Test (QS-PST). While researchers have extensively investigated QS-PST in FRP composites through experimental and numerical approaches, there's a notable gap in studies addressing the aging effects through both experimental and numerical methods. In this study, the QS-PST was conducted on S2 glass fiber reinforced epoxy composite materials aged in an artificial seawater environment. Composite plates were fabricated using Vacuum-assisted resin transfer molding (VARTM). Test samples were subjected to aging for durations of 4, 8, and 12 months. Experimental QS-PST were performed on the samples, followed by Finite Element Analysis (FEA) using LS-DYNA and the MAT 162 material model. The mechanical properties of the composite material were incorporated into the FEA and aging effects were simulated with a maximum error of 8.08% by using the proposed material model. The results indicated that the aging process led to a reduction in the punch shear strength of the composite by up to 26.84%. These findings provide valuable insights into the degradation mechanisms of composite materials in marine environments, aiding in the development of strategies for enhanced durability and performance in such conditions.

An efficient ultrasound vibration strategy for suppressing intra-bundle pores and regulating pore morphology in carbon fiber-reinforced composites

The competitive resin flow between intra- and inter-bundles, always causes the generation of intra-bundle pores during resin transfer molding (RTM), thereby weakening composite mechanical performance. Accordingly, an ultrasound vibration strategy is originally developed to efficiently suppress and improve the spatial morphology and distribution of intra-bundle pores in RTM manufacturing. The effects of ultrasound vibration on the spatial evolution of intra-bundle pores are systematically investigated, furthermore, the suppression mechanisms of intra-bundle pores are revealed. Additionally, an empirical model that predicts porosity under ultrasound vibration, is established and well validated for the developed ultrasound vibration strategy, which provides a feasible path for effectively manufacturing composites. X-ray micro-computed tomography experiments verify that applying a short period of ultrasound vibration balances the dual-scale flow by regulating the modified capillary number, thereby significantly reducing porosity by up to 59.4 %. Numerical analyses indicate that the acoustic cavitation and acoustic flow induced by the ultrasound vibration, facilitate the collapse and transverse migration of larger bubbles, thereby remarkably suppressing the connected pores and larger pores. In particular, the ultrasound vibration strategy completely removes the pores larger than 300 μm. Besides, the collective effects of vibration, compression, and shear forces contribute to forming near-circular pores, which are beneficial for ensuring the expected mechanical performance of composites.

A New Approach for Improving Flame Retardancy of Automotive Interior Upholstery

This study presents the flame retardant (FR) performance of chemically treated automotive upholstery fabrics using two different impregnation methods of Resin Transfer Molding (RTM) and supercritical carbon dioxide (scCO2). Referring to the related standards, untreated seat fabric obtained from seat upholstery of a bus (neat fabric, NF) and treated fabric samples underwent burning rate (BR) and limiting oxygen index (LOI) tests to compare effect of treatment and impregnation methods on FR performance. Thermal analysis was also conducted on the samples considering onset degradation temperatures and char yields. The results showed that BR and LOI of all samples were in acceptable range and treatment provided enhancement in FR performance of NF. The treated sample using scCO2 method gave the highest LOI value of 32% and the lowest BR of 21 mm/min subtending to 18.5% increase in LOI and 30% reduction in BR compared to those of NF. The performance of treatment in RTM was worse than that of scCO2 and better than that of NF. The results confirm that both treatment and methods used in this study give promising results for safety against fire in transportation vehicles.

Comprehensive Analysis of the Effect of Braiding Angle on the Wettability and Mechanical Properties of 3D Braided Carbon Fiber Fabric-Reinforced Composites

Fiber-reinforced composites are designed to enhance strength, stiffness, and lightweight properties. However, while the use of continuous fibers offer substantial performance benefits it presents challenges in achieving complex configurations. This study focused on evaluating the effects of different braiding angles on the mechanical properties of braided fabric-reinforced composites (B-CFRP). Continuous fiber tows were braided around a mandrel, with meticulous control over the key process parameters to ensure consistency. The composites were then processed using the Vacuum Assisted Resin Transfer Molding (VARTM) technique to achieve optimal impregnation of the resin. Mechanical properties, including tensile, flexural, compressive strength, interlaminar shear strength (ILSS), and impact strength, were performed to establish the relationship between resin impregnation and mechanical properties with different braid angles. Additionally, resin flow experiments and scanning electron microscopy (SEM) analysis were conducted to investigate how variations in braiding angle influence fiber arrangement, resin distribution, and fracture behavior. These insights aim to guide the design and manufacturing of high-performance composites.

Curved surface coupled structural battery composites manufactured by resin transfer molding process: Microstructure and multifunctional performance

To bridge industrial production and lab-scale research, this work demonstrates a technology to manufacture curved surface structural battery composites (CSBCs) that can simultaneously achieve electrochemical energy storage and load-bearing. The curved-surface carbon fiber structural anode and cathode are fabricated by coating the active materials on carbon fiber fabric with a vacuum-bag-assisted technique. The resin transfer molding (RTM) process is conducted to manufacture the coupled CSBCs by infusing bi-continuous phase epoxy resin electrolyte and curing at high temperatures. The microstructure of structural electrodes and CSBCs is characterized by scanning electron microscopy (SEM). Due to good interfacial compatibility between high mechanical strength carbon fiber structural electrode and high ionic conductivity solid polymer electrolyte bulk for load support, the fabricated CSBCs demonstrate a high density of 294 mWh kg−1 based on the whole mass of devices, a tensile strength of 257.4 MPa with Young's modulus of 12.9 GPa and a flexural strength of 194.1 MPa with flexural modulus of 11.1 GPa. In situ electrochemical-mechanical tests further confirm the durability of CSBCs under mechanical loads with a multifunctional efficiency of 1.07, suggesting the effectiveness of the introduced manufacturing techniques for coupled structural battery composites.

Influence of Calcination and Cation Exchange (APTES) of Bentonite-Modified Reinforced Basalt/Epoxy Multiscale Composites’ Mechanical and Wear Performance: A Comparative Study

In this study, bentonite clay was modified through silane treatment and calcination to enhance its compatibility with basalt fiber (BF) and epoxy in multiscale composites. The as-received bentonite (ARB) was subjected to silane treatment using APTES, producing silane-modified bentonite (STB), while calcination yielded calcined bentonite (CB). The modified clays were incorporated into basalt fiber-reinforced epoxy (BFRP) composites, which were fabricated using the vacuum-assisted resin transfer method (VARTM). Analytical techniques, including X-ray diffraction (XRD) and Fourier-transform infrared (FTIR) spectroscopy, confirmed the structural changes in the clays. BET surface area analysis revealed a 314% increase in the surface area of STB and a 176% increase for CB. The modified clays also demonstrated reduced hydrophilicity and swelling behavior. Thermogravimetric analysis (TGA) indicated a minimal improvement in thermal stability, with the degradation onset temperatures increasing by less than 3 °C. However, tensile tests showed significant gains, with CB- and STB-reinforced composites achieving 48% and 21% higher tensile strength than ARB-reinforced composites. Tribological tests revealed substantial reductions in wear, with CB- and STB-reinforced composites showing 90% and 84% decreases in the wear volume, respectively. These findings highlight the potential of modified bentonite clays to improve the mechanical and wear properties of basalt fiber–epoxy composites.

Nano aluminum nitride fillers for enhanced mechanical and thermal properties of GFRP in cryogenic temperature settings

Glass fiber-reinforced polymer (GFRP) composites, with epoxy resin or a blend of cyanate and epoxy resins as the matrix, have been used as insulating materials of high-field, large-scale superconducting magnets for accelerators and magnetic confinement fusion. However, the GFRP does not fully meet the requirements for the next generation of magnetic confinement fusion with respect to the mechanical and thermal performance at cryogenic temperature and huge electromagnetic stress. This paper introduces a method for enhancing both the mechanical and thermal properties of the GFRP composites using aluminum nitride (AlN) nanoparticles. The fabrication of the AlN-GFRP composite involved a method that combines “dip absorption” with vacuum-assisted resin transfer molding (VARTM). The dip absorption method was utilized to deposit AlN nanopowders onto glass fibers, resulting in the preparation of AlN-glass fiber layers. Subsequently, the AlN-woven glass fibers were incorporated to reinforce the cyanate ester/epoxy based composites using the VARTM technology. The mechanical and thermal properties of the AlN-GFRP composites were assessed across varying temperatures. The results indicate that the short-beam shear strength (SBS strength) of the AlN-GFRP composites improves at cryogenic temperatures compared to that of the GFRP composites without AlN. Additionally, enhanced thermal conductivities are observed across different temperature ranges for the AlN-GFRP composites. The coefficient of thermal expansion between 77 K and 300 K of the composites significantly decreases with the addition of the AlN nanopowders.

Design-manufacturing-performance of electromagnetic absorbing/load bearing three-dimensional honeycomb woven composites

Structural electromagnetic wave (EMW) absorbing composites play a critical role in both civilian and military applications. However, traditional sandwich honeycomb EMW absorbing composites have poor out-of-plane mechanical properties and load-bearing performance.This study introduces the development of a three-dimensional honeycomb woven composite (3DHWC) that integrates EMW absorption and load-bearing capabilities. A weaving loom was used to fabricate a three-dimensional honeycomb woven structure fabric (3DHSWF) with varying structural parameters. Subsequently, the composites were formed using carbon black (CB), multi-walled carbon nanotubes (MWCNTs), and carbonyl iron powder (CIP) as hybrid absorbers, epoxy resin as the matrix, combined with the vacuum-assisted resin transfer molding (VARTM) process. Testing confirmed the material’s excellent EMW absorption and mechanical properties, achieving a maximum reflection loss (RL) of −30.9 dB and an adequate EMW absorption bandwidth (EAB) of 14.58 GHz. The maximum bending load reached 5799.1 N, with no delamination observed in the samples. This material demonstrates outstanding EMW absorption performance and exhibits superior load-bearing capacity while maintaining structural integrity. Our research provides valuable insights into the design of honeycomb EMW absorbing composites, offering significant advancements in EMW absorption efficiency and bending mechanical properties.

Defect detection on RTM composite parts via robotic contact measurement system

In this work a new approach to detect and to evaluate defects typical of carbon fiber parts manufactured via resin transfer molding (RTM) is presented. The approach is based on a robotic contact measurement system, as an alternative or combined solution to vision methods. The research is meant to provide more accurate local geometry information to the global information acquired using vision systems. The system consists of a collaborative robot equipped with a force-torque sensor that scans the surface of the workpiece with a defined motion strategy. To evaluate the system, tests were conducted on a 3D printed part presenting a feature representative of the defects found on carbon fiber components. The results are compared with the CAD model and data acquired using a structured light scanner, showing that robotic contact measurement can be a viable method to enhance the reconstruction of a part with a higher accuracy. The system is then applied and validated on a real part made with RTM.

Effects of temperature and loading rate on the shear performance of GFRP-steel single-lap joints

This research examines how the shear properties of glass fiber-reinforced polymer (GFRP) and steel single-lap joints react under various temperatures (−25, 0, 25, 50, and 100℃) and loading speeds (0.625, 1.25, 2.5, and 5.0 m/s). The GFRP sheets, aligned unidirectionally, were produced using vacuum-assisted resin transfer molding and were then adhesively attached to steel plates with epoxy resin. The assemblies were subjected to a high-speed servo-hydraulic testing apparatus for evaluation. The results indicate that the joint's performance is relatively unaffected by changes in the loading speed, but the overall toughness tends to decrease at higher speeds. However, the adhesive bond strength increases when temperatures are between −25 and 50℃ but diminishes as temperatures rise from 50 to 100℃. Most samples exhibited debonding at the steel-adhesive interface under varied speeds and colder temperatures, whereas debonding at the GFRP-adhesive interface was more prevalent at elevated temperatures. These insights are vital for both theoretical analyses and practical implementations of GFRP-steel single-lap joints in environments subject to extreme loading conditions and temperatures.

Impact response and compression-after-impact properties of foam-core sandwich composites incorporating scrap tyre rubber particles

Integrating scrap rubber particles as fillers into polymer matrix composites offers a cost effective and environmentally sustainable pathway to manage tyre waste through the creation of value-added products. This research explores the low-velocity impact (LVI) response and compression after impact (CAI) properties of rubberised foam-core glass fibre-reinforced epoxy (GFRE) sandwich composites. Syntactic foam cores integrated with rubber particles were manufactured using vacuum-assisted resin transfer moulding (VARTM). The compression properties of rubberised foam core, vital for resisting impact damage during LVI, were examined. Results show more than 40% reduction in compression strength and modulus of the syntactic foam upon the inclusion of 33 wt.% rubber particles. The LVI response and residual compression properties of rubberised foam-core composites were also evaluated. Rubberised foam cores caused a marginal reduction in the peak impact force and led to approximately 60% reduction in the delamination area. The pre-impact compression strength was unaffected by rubber particles within the core as the GFRE face sheets carried most of the compression load. Post-impact compression strength was slightly higher in rubberised foam-core composites due to reduced delamination. Digital Image Correlation (DIC) analysis tracking of the strain evolution during CAI experiments revealed the stress-raising effect of the impact damaged region. This study showcases sustainable scrap tyre management through the inclusion of rubber particles into foam-core composites without substantially reducing in-plane compression properties before or after low-velocity impact.

Comparison of single- and hybrid-fiber composite laminates for use in prosthetic sockets

Traditional prosthetic sockets often consist of thermoplastic and wood-based materials. However, these sockets are known to be uncomfortable, heavy, and economically challenging. Natural fibers are quickly adapting and becoming more popular because of their biodegradable, long-lasting, and biocompatible nature. They are replacing synthetic fibers in the design and development of structural parts. This research looked into a new hybrid composite made of natural and synthetic fibers (basalt, jute, and carbon) that are reinforced in a polyester thermoset based matrix. The performance of this hybrid composite was then compared to that of pristine or single fiber-reinforced composites manufactured using woven jute, basalt, and carbon. The samples were manufactured using the vacuum-assisted resin transfer molding technique and cured at room temperature. The samples were then subjected to flexure and impact tests. The hybrid composite had an impact strength of 46.71 kJ/m2, higher than all other single fiber combinations. The flexural strength of the hybrid composite was determined to be 66.25 MPa, matching that of basalt fiber and surpassing that of other conventional single fiber composite laminates. Fractographic analysis has revealed that the main cause of failure in flexure is mostly attributed to delamination and fiber micro-buckling. Although hybrid reinforced composites had superior performance in terms of both impact and flexure strength, basalt fibers demonstrated comparable strength, specifically in flexure. Overall, the hybrid composite possesses exceptional promise for use in prosthetic construction.

Multi-scale characterization of self-sensing fiber reinforced composites

The piezoresistive properties of fiber-based embedded sensors across tow, fabric, and laminate scales offer opportunities for their efficient application in fiber reinforced polymer composite (FRPC) structures. This study involves the multi-scale characterization of rGO-coated glass fiber tows, fabric, and laminates produced via vacuum assisted resin transfer molding (VARTM). The study demonstrates how fiber type, areal weight, and architecture affect piezoresistivity in rGO-coated glass fiber-based sensors subjected to in-plane tensile loading. In this study, rGO-coated glass fiber tows, with three linear densities (138, 1200, 1232 TEX), were examined. Fabric-level sensors, including plain weave (PW), and quadriaxial (QUAD), with areal densities of 200, 600, and 807 g/m2 were also studied. For comparison, laminates using UD carbon fabrics (300 g/m2) were employed as embedded piezoresistive sensors in the glass fiber-based laminates. It has been shown that rGO-coated sensors with lower areal weights outperformed all other sensor types in terms of their piezoresistive characteristics. This study suggests that piezoresistive sensors offer significant potential for use in load-bearing structural applications which can be further enhanced by investigating their lower scales.

Additively manufactured resin transfer molding (RTM) plastic tooling for producing composite T-joint structures

Additively manufactured resin transfer molding (RTM) plastic tooling for producing composite T-joint structures

Horn sheath-inspired lightweight composites with enhanced impact resistance

The natural Caprinae horn sheaths possess excellent mechanical properties due to the synergistic effects of the porous and corrugated lamellar structure. However, research on bioinspired designs based on this structure remains absent. In this work, we attempted to integrate hollow glass microspheres modified by silane coupling agents into A. pernyi silk fabric, and finally fabricate a horn sheath-inspired composite using the vacuum-assisted resin transfer molding. The impact strength of the horn sheath-inspired composite reaches up to 150 kJ m-2 with a low density of 1290 kg m-³. Fracture morphology analysis and finite element simulation confirmed the toughening mechanisms, including crack deflection and interfacial bonding due to the synergistic effects of the porous structure and the corrugated silk fabrics. This study provides a bioinspired strategy to lightweight and tough composites, with significant potential in impact-critical applications.

Induction heating simulation for aircraft RTM toolings

Aircraft CFRP parts as sharklets are produced in resin transfer molding (RTM) tooling. The parts need to be heated up homogenously over the whole area with a constant temperature. The complex shape and accessibility of the tooling make it hard to introduce a common heating system. In addition, the heat must be transferred through the Invar metal tooling structure onto the CFRP. Infrared lamp, air fan and microwave heating are concepts in development. Electrical heating layer mats and cages are laborious in applying. Induction has the advantage of contact-less, efficient, and fast heating. Induction heating was tested for the structural bonding of CFRP frames and stringers showing high bonding strengths. To apply this technology for the RTM tooling, the placement and distance of the induction coils is important. Simulation can help to find the right adjustments and power needed for induction heating. With the program COMSOL the surface and the coils are modeled, and the numerically structured net is divided in small tetrahedron and quadratic sub elements. Since there is no magnetic streamline in the middle of the coil-section, a symmetric halving of the structure is applied as a boundary condition. The temperature-time development and the distance of the coils are simulated in 2D and 3D. Due to the material properties of the magnetic flux concentrator (MFC), higher flux concentration of the magnetic field occurred only in 2D. The results are validated by experiments and are in good agreement.

Experimental and numerical investigation of damage in multilayer sandwich panels with square and trapezoidal corrugated cores under quasi-static three-point bending

Multilayer composite sandwich panels with corrugated cores have the potential for structural applications requiring high stiffness and strength-to-weight ratios. This study aims to experimentally and numerically investigate the bending response of sandwich panels with novel square and trapezoidal corrugated core configurations fabricated from E-glass fiber-reinforced epoxy composites, both with and without polyurethane foam filling. Quasi-static three-point bending tests were conducted to evaluate and compare the flexural stiffness and maximum load capacity of the panel designs. The cores were manufactured using vacuum-assisted resin transfer molding. Key results showed that changing the core geometry from square to trapezoidal improved the bending stiffness by up to 26 %. Incorporating polyurethane foam further increased the bending stiffness by up to 41 % and maximum load by up to 47 % compared to solid cores. Failure initiation and progression were governed by matrix cracking in the face sheets and cores, followed by core cell wall buckling and delamination. Finite element modeling using ABAQUS captured the progressive damage behavior, exhibiting good agreement with experimental force-displacement responses. Failure modes included matrix cracks, fiber fractures, core buckling and delamination. This study provides valuable insights into the mechanical performance of innovative corrugated core sandwich panel designs under quasi-static bending loads. The validated FE approach also enables virtual testing and optimization of composite sandwich structures.