Liquid composite molding reproducibility in real-world production of fiber reinforced polymeric composites: a review of challenges and solutions

Abstract

Liquid composite molding (LCM) suffers from multiple factors that contribute to pronounced uncertainty of process characteristics. This results in compromised reproducibility which is associated to high scrap or the unpredictable behavior of approved parts. However, LCM is still attractive for Fiber-reinforced polymeric composites (FRPC) production due to its economic advantage (i.e. in relation to Autoclave), the capability of some of its variants to produce high performance parts and its potential for process optimization. This review analyzes each uncertainty with respect to its origins and its impact in part or process, based on a combination of past literature and original numerical results. The possible methods to counteract uncertainties are critically discussed, with an eye on both the scientific and feasibility (technical/economical) aspects. The overall aim is to provide to future LCM implementations a roadmap of the most critical challenges and solutions regarding the establishment of a reproducible process.

Manufacturing Technologies of Carbon/Glass Fiber-Reinforced Polymer Composites and Their Properties: A Review

“…All these defects lead to a decrease in strength and modulus, which finally initiates a premature failure of the composite. Konstantopoulos et al [70] provide a good overview of the solutions and challenges in the field of liquid composite molding procedures, while van Oosterom et al [71] compare different infusion techniques in terms of process and mechanical parameters. Therefore, to address some of the limitations of the VARTM process, future research directions should focus on several issues, including optimal design and manufacture of the preform (to achieve good control of permeability and compaction), development of a new resin system with viscosity and cure kinetics, improving the filling/infusion time of the resin compartments, development of reusable packaging systems, improving flow and curing control and increasing reliability in detecting and remedying leaks during the process [72].…”

Usage of Near-Infrared Spectroscopy for Inline Monitoring the Degree of Curing in RTM Processes

“…Since easy prototype manufacturing, as well as highly automated series production, is possible, LCM processing is widely used. Especially for series production, process optimization [ 2 ] and reproducibility are gaining importance [ 3 ]. With increased automatization in the field of processing composites, efficient inline monitoring techniques are required to ensure process stability and quality.…”

Life-Cycle Monitoring of CFRP using Piezoelectric Sensors Network

“…As a new type of low-cost molding technology for large-scale composite materials with the advantages of excellent product performance, low porosity and good adaptability [2,3], the VARI has attracted more and more attention in the field of aviation and spaceflight. However, there are still many difficulties in the VARI process, such as the control of the resin flow, the prevention of dry spots and the delamination and residual stress that closely related to the control parameter of the process [4,5].…”