Experimental Evaluation of Co-Infusion as a Viable Method for In-Mold Coating of Composite Components

Solomon, Fouad A.; Okoli, Okenwa I.

doi:10.1177/0731684408090714

Cited by 5 publications

(3 citation statements)

References 9 publications

(28 reference statements)

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“…Infusion of the matrix resin at the same time as a polyurethane enamel paint (DuPont Imron 5000), coating layer in the same flexible mould (Chiu and Okoli, 2006;Thagard et al, 2004;Chiu, 2004) was suggested for potential development if an appropriate separation layer could be developed. Solomon (2009) enhanced the separation of the two fluids by eliminating the use of a single vacuum flow path for the coating and the resin. Similarly, a technique using thermo formable paint films (Toro et al, 2005) was proven to be viable but needed further development of the paint film, allowing it to fully adhere within the resin gel time at elevated temperatures.…”

Section: Resin Infusion Under Double Flexible Tooling (Ridft)mentioning

confidence: 99%

In-mould gel-coating of polymer composites: a review

Rogers

Hoppins²,

Gombos

et al. 2014

Journal of Cleaner Production

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Fibre-reinforced polymer matrix composites find use in most transport applications, chemical plant, renewable energy systems, pipelines and a variety of other industries. These applications often require a surface finish for cosmetic and/or durability reasons. The coating is usually polyester or vinyl-ester gel-coat painted or sprayed onto the mould tool before the structural composite is laminated. Alternatively a (typically polyurea) coating may be sprayed onto the surface of the cured composite part. The process may emit vapours (normally volatile organic compounds, VOC) into the workplace and the environment. This review paper will consider the potential for in-mould gel-coating as a route to improved workplace conditions and reduced environmental impact. It will also address measurement of quality by adhesion, surface characterisation, and long-term durability. Customer satisfaction is the key driver for gel-coated products.

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Section: Resin Infusion Under Double Flexible Tooling (Ridft)mentioning

confidence: 99%

In-mould gel-coating of polymer composites: a review

Rogers

Hoppins²,

Gombos

et al. 2014

Journal of Cleaner Production

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“…Different from traditional RTM process like RIDFT (Resin Infusion between Double Tooling), this method uses two sets of RTM injection systems to inject two distinctive types of resin independently and simultaneously into the mold, which is filled with fiber preform and vacuumized beforehand. 15–19 This course is called “co-injection”, whose detailed illustration is as shown in Figure 2. Fiber preform A and fiber preform B made from carbon fiber plain fabrics refer to two preforms used to make the carbon/epoxy layer and carbon/phenolic layer of the sandwich panel.…”

Section: Manufacture Processingmentioning

confidence: 99%

Composite sandwich panel with multifunction of load bearing, heat insulation, and thermal protection

Chen

Zheng

Zeng

et al. 2014

Journal of Composite Materials

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Integrative sandwich panels with multifunction of load bearing, thermal protection, and heat insulation are manufactured through co-injection resin transfer molding process. These panels have a polymethacrylimide foam core for heat insulation and two composite layers made of carbon/epoxy for load bearing and carbon/phenolic for thermal protection. In co-injection resin transfer molding process, the epoxy resin and phenolic resin are synchronously injected and cured in order to make integrative structures and improve the properties of the interface between different layers. The influence of main factors in the process of co-injection is investigated: the vacuum assistance is indispensable to improve the efficiency of manufacture and guarantee the properties of the products, volume fraction of carbon fiber plays the main role in determining size accuracy of the product, adjusting injection pressure is a simple and efficient way to adjust the infusion time of resin, while injection temperature has smaller influence in the features of manufacture. The mechanical properties of sandwich panels manufactured through co-injection resin transfer molding process and multi-step process are tested and compared to validate the advantage of the co-injection resin transfer molding process. The test shows that the in-plane compressive strength, three-point flexural strength, and interface shear strength are all improved by the co-injection resin transfer molding process. Co-injection resin transfer molding process is proved to be a feasible and efficient way to manufacture the integrative sandwich panel with good interface features.

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“…Apart from conventional coating or painting a component after being moulded, other alternatives of coating include applying the corresponding coat onto the mould before placing the preform [275], injecting the coat between the mould and the components after being moulded [279], placing a thermoformable film between the preform and the mould [280,281], and coinfusing the coat and the matrix [282][283][284]. The last three listed procedures would be compatible with ISFLIP, being the thermoformable film method a specially interesting technology to be combined with.…”

Section: Look and Feel And Roughnessmentioning

confidence: 99%

Development of the in situ forming of a liquid infused preform (ISFLIP) process : a new manufacturing technique for high performance fibre reinforced polymer (FRP) components

Juan Muñoz

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A problem is not a problem anymore if no solution exists; therefore, in the present dissertation, a novel manufacturing technique, the In Situ Forming of a Liquid Infused Preform (ISFLIP), is proposed as a solution to some typical problems that manufacturing of Fibre Reinforced Polymer (FRP) parts through Vacuum Infusion (VI) involves, such as not taking advantage of the full potential of FRPs, long processing times and lack of reproducibility. ISFLIP is a hybrid process between VI and diaphragm forming in which a flat preform of a stack of reinforcement fabrics is firstly impregnated with a low viscosity matrix and, then, formed over a mould while the matrix is still in the low viscosity state. Being focused on high performance FRPs and shell components, from simple to complex double curvature shapes, a number of trade-offs between VI and diaphragm forming were overcome to lay the foundations from which ISFLIP ability to manufacture FRP components has been proven. In order to adopt a VI manufacturing methodology that fitted ISFLIP targets, important contributions to more general VI have also been made in terms of part quality optimization, addressing the major concern that void content is in VI, with competitive manufacturing times. An effective vacuum degassing procedure in which bubble formation is enhanced through high speed stirring, and a non-conventional filling and post-filling strategy are proposed for this purpose. Eventually, void content was virtually eliminated and post-filling time minimized without affecting fibre content. In ISFLIP, textile preforms are formed together with a series of auxiliary materials (plastic films and sheets, textile fabrics and knitted meshes), most of them showing different in-plane deformation mechanisms. Forming performance of preforms, as well as final part quality, are severely affected by interactions between all these materials different in nature. Uncertainties on this respect and an initial evaluation of attainable shapes were also addressed to define a more focused research plan to the final goal, still distant, of implementing ISFLIP in a real production environment. Results obtained throughout the research project give cause for reasonable optimism in ISFLIP potential and future prospects. Un problema deja de ser un problema si no existe solución; por lo tanto, en esta disertación, una novedosa técnica de fabricación, el Conformado In Situ de una Preforma Infusionada con resina Líquida (ISFLIP, por sus siglas en inglés), se propone como solución a algunos problemas típicos relacionados con la fabricación de piezas de Polímero Reforzado con Fibra (FRP) a través de la Infusión por Vacío (VI), problemas tales como el desaprovechamiento de todo el potencial de los FRPs, largos tiempos de procesado y falta de reproducibilidad. ISFLIP es un proceso híbrido entre la VI y el conformado por membrana elástica en el que una preforma plana formada a partir de un apilado de tejidos de refuerzo es en primera instancia impregnada con una resina de baja viscosidad y, entonces, conformada sobre un molde mientras que la matriz permanece todavía en el estado de baja viscosidad. Estando centrado en los FRPs de altas prestaciones y en componentes con formas tipo concha, desde curvaturas simples hasta formas con doble curvatura complejas, un número importante de compensaciones entre la VI y el conformado por membrana se han ido superando para asentar las bases a partir de las cuales se ha probado la capacidad de ISFLIP para fabricas componentes de FRP. Con la vista puesta en implementar una metodología de fabricación por VI que cumpliese los objetivos definidos para ISFLIP, también se han realizado importantes contribuciones de carácter más general relacionadas con la VI en términos de optimización de parámetros de calidad de las piezas, abordando la gran preocupación que la porosidad final supone en la VI, y consiguiendo unos tiempos de fabricación competitivos. Con este propósito se han propuesto un proceso de desgasificación por vacío muy efectivo en el que se favorece la nucleación de burbujas mediante la agitación a alta velocidad, y una prometedora y no convencional estrategia de llenado y post-llenado de la preforma. Finalmente, se consiguió virtualmente eliminar la porosidad atrapada en las piezas, minimizando el tiempo de post-llenado sin afectar la fracción de fibra contenida. En ISFLIP las preformas textiles se conforman junto con una serie de materiales auxiliares (films y hojas plásticas, mallas y tejidos textiles), que muestran diferentes mecanismos de deformación en plano. El conformado de las preformas y el acabado final de las piezas se ve severamente afectado por todas las interacciones entre todos estos materiales diferentes en naturaleza. También se han abordado las incertidumbres que surgen al respecto y una evaluación inicial de las geometrías abarcables para definir un plan de investigación más concreto con el que poder afrontar la meta final, todavía distante, de implementar ISFLIP en un entorno productivo real. Los resultados obtenidos a lo largo de este proyecto de investigación permiten ser razonablemente optimistas en cuanto al potencial de ISFLIP y sus expectativas.

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Experimental Evaluation of Co-Infusion as a Viable Method for In-Mold Coating of Composite Components

Cited by 5 publications

References 9 publications

In-mould gel-coating of polymer composites: a review

In-mould gel-coating of polymer composites: a review

Composite sandwich panel with multifunction of load bearing, heat insulation, and thermal protection

Development of the in situ forming of a liquid infused preform (ISFLIP) process : a new manufacturing technique for high performance fibre reinforced polymer (FRP) components

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