08 Maria Odila Cioffi Workshop Estruturas Leves 20mai2014

1
Process and Characterization

of Composite by RTM
Maria Odila Hilrio Cioffi
cioffi@feg.unesp.br
Fatigue and Aeronautic Materials Research Group
2 2
3 3
18 Researchers
21 Students
1 Technician
4
Project
General Objectives:
Development of an
experimental
methodology to
produce aeronautical
components by resin
transfer molding
process;
Substitution of Al7050-
T7451 alloy by non-
crimp fabric
(NCF)/epoxy system
(RTM6) composites;
EMBRAER Landing Gear
HYDRAULIC
CYLINDERS
SHOCK
ABSORBER
SHAFT
STALK
5
Project
General Objectives:
Development of an
experimental
methodology to
components by resin
transfer molding
process;
T7451 alloy by non-
crimp fabric
(NCF)/epoxy system
(RTM6) composites;
HYDRAULIC
CYLINDERS
SHOCK
ABSORBER
SHAFT
STALK
6
Project
General Objectives:
Development of an
experimental
methodology to
components by resin
transfer molding
process;
T7451 alloy by non-
crimp fabric
(NCF)/epoxy system
(RTM6) composites;
HYDRAULIC
CYLINDERS
SHOCK
ABSORBER
SHAFT
STALK
Properties
Materials
Al 7050-T7451 NC2/RTM6
Elastic Modulus 65 GPa 60 GPa
Yield Strength 429 MPa 530 MPa
Ultimate Tensile Strength 502 MPa 665 MPa
Elongation 10 % 2 %
7
Project
General Objectives:
Development of an
experimental
methodology to
components by resin
transfer molding
process;
T7451 alloy by non-
crimp fabric
(NCF)/epoxy system
(RTM6) composites;
HYDRAULIC
CYLINDERS
SHOCK
ABSORBER
SHAFT
STALK
Properties
Materials
Al 7050-T7451 NC2/RTM6
Elastic Modulus 65 GPa 60 GPa
Yield Strength 429 MPa 530 MPa
Ultimate Tensile Strength 502 MPa 665 MPa
Elongation 10 % 2 %
Materials change will provide a reduction
of 59% weight for the component.
8
400
420
440
460
480
500
10000 100000 1000000
Delamination
Rupture
N (cycles)
S
t
r
e
s
s

(
M
P
a
)
Fatigue Tests
SxN Curve. NC2/RTM6Composite.
Results
9
400
420
440
460
480
500
10000 100000 1000000
Delamination
Rupture
N (cycles)
S
t
r
e
s
s

(
M
P
a
)
Fatigue Tests
SxN Curve. NC2/RTM6Composite.
Results
hackles
cusps
10
Process
Matrix
Toughness
Kinetic Study
Reinforcement
Stitching
Drapability
Permeability
Process
Process Parameters influence
Cure cycle
Composites
Acoustic inspection Microscopy
11
Matrix
Toughness:
Impregnation Map of NCF/RTM6
composite
3-D construction C-scan Map:
NCF/RTM6 composite
12
Matrix
Toughness:
Impregnation Map of NCF/RTM6
composite
3-D construction C-scan Map:
NCF/RTM6 composite
13
Toughness:
Matrix
HPBA polymer was more
efficient due to molecule
higher free volume and
suitable physical interaction
with epoxy system
Sea-island
14
Matrix
Kinetic reaction Prism EP2400
Dynamic DSC for 2, 5 e 10C
Isothermal coversion Curve
Dynamic DSC for different heating rates;
Simulation of isothermals by isoconversional method;
The difference between the theoretic and experimental method is associated
by autocatalytic and n order kinetic reactions
15
Matrix
kinetic study Prism EP2400
Experimental curves of rate and isothermal
conversion at 170, 175 e 180C.
Time function fitting experimental curve
Conversion rates by DSC autocatalytic model until 50 min for T
cura
.
As the cure progress n order model .
16
Stitching
Tricot Stitching
Chain Stitching
Stitching influence
Chain showed a fatigue behavior more uniforme due to the homogeneous stitching
Higher fatigue behavior was observed when the stitching was tricot but with
premature delaminatin process
17
Stitching
Tricot Stitching
Chain Stitching
Stitching influence
Chain showed a fatigue behavior more uniforme due to the homogeneous stitching
Higher fatigue behavior was observed when the stitching was tricot but with
premature delaminatin process
18
Reinforcement
Drapability
19
Reinforcement
Drapability
20
Reinforcement
Drapability
21
Reinforcement
Drapability
22
Reinforcement
Drapability
23
Permeability: experimental X Simulation

Reinforcement
It was also observed the race tracking phenomena for both model and
experimental
The same resin front behavior was observed for both until 2/3 fabric
length.
24

Reinforcement
From this point the fluid become different.
25

Reinforcement
26

Reinforcement
At the end of the fabric length the front is equal again.

The simulation and the mesh model are suitable
Total time of injection t = 2342 s (model 4747 elements).
Permeability study t = 1137 s.
27

Reinforcement
28
RTM Process
FAPESP processo nmero 2006/02121-6 - JP
29
Process RTM
Process parameter influence:
Temperature:
Enough to reduce the resin viscosity in order to promote high
volume fiber impregnation;
High Viscosity produce fiber misalignment.
Pressure:
Enough to improve the impregnation (1.5 4.0 bar);
Excessive pressure produce fiber misalignment.
Fiber volume fraction:
Constant throughout the laminate in order to avoid preferential
resin path, which cause dry spots.
30
RTM Process
Cure cycle:
Set by kinetic study ;
low temperature rate improves the fabric impregnation;
longer periods of low viscosity resin within the first 25 min 50 mPa.s
31
Composite
Procedure for acoustic microscopy inspection - MIScan

Ultrasonic inspection
A-scan and C-scan method
Transducer 10 MHz probe
Pulse-echo mode

Equipment Model PSS-600, MUIS32 manufactured by MATEC
A-scan graphic aided to calibrate the patterns of typical composite peaks
32
Composite

Pulse-echo mode

INJEO
a)

INJEO
b)

Figura 6.23 Efeito de race-tracking detectado no ultrassom: a) gate 1; b) gate 2

33
Composite

Pulse-echo mode

INJEO
a)
INJEO
b)
a)
Developments
Advanced
Composites
Crack propagation in 5HS carbon/epoxy composites
Interlaminar Fracture Toughness Study
Structural composite fatigue life prediction considering
DMA results
Natural
composite
Thermoplastics composites obtained by injection
Thermossseting composites by RTM process
Nanobiodegradable composites by electrospinning
Composites development to historic edification application
34
Research
RTM linked projects
Projects
Projetos
Aquisio dos seguintes equipamentos:
Injetora Radius 2100cc RTM
Molde fechado em ao
Sistema de aquecimento via resistncias eltricas
Bomba de vcuo
Microscpio de varredura acstica (MIScan)
Estufa a vcuo, agitadores e balana analtica
CNPq n 472570/2006-4

FAPESP n 2006/02121-6
Projetos
Figura XX: Sistema de processamento de compsitos por RTM locado no DMT/FEG/UNESP
Projetos
Figura XX: Detalhes do molde em ao usando no processamento via RTM
Projetos
Figura XX: : Equipamento de ultrassom por imerso em gua locado no DMT/FEG/UNESP
Projetos
Porosmetro Automtico de Mercrio, modelo Poremaster 33 GT
(Quantachrome Instruments)
Descrio: Realiza medies de tamanho de poros de distribuio em
duas amostras de gerao de presso contnua ou gradual de vcuo
para 33.000 psi.
CNPq n 483308/2010-2
Titulo do Projeto: PROCESSAMENTO DE COMPSITOS VIA RTM:
CONTROLE DE VAZIOS POR DIFERENTES METODOLOGIAS
Projetos
Figura XX: Porosmetro Automtico de Mercrio locado no DMT/FEG/UNESP
Projetos
Analisador de Densidade Real, Modelo UltraFoam 1200e
(Quantachrome Instruments)
Descrio: Determina o volume real/densidade de slidos.
CNPq n 483308/2010-2
Projetos
Figura XX: Analisador de Densidade Real locado no DMT/FEG/UNESP
Projetos
Cortadeira Metalogrfica TechCut-5 (Allied High Tech Products)
Descrio: Cortadeira metalogrfica com avano automtico.
CNPq n 483308/2010-2
Projetos
Figura XX: Cortadeira metalogrfica locada no DMT/FEG/UNESP
Projetos
Aquisio do seguinte equipamento:
Equipamento de Calorimetria Exploratria Diferencial (DSC) com
compensao de potncia, modelo DSC 8000 (PerkinElmer)
Descrio: Esse equipamento tem a capacidade de operar em uma
faixa de temperatura de trabalho de -180C at 750C com taxas de
aquecimento e resfriamento de 1 a 750C/min.
CNPq n 486083/2012-8
CARACTERIZAO TRMICA
Projetos
Figura XX: DSC 8000 (equipamento em fase de importao)

08 Maria Odila Cioffi Workshop Estruturas Leves 20mai2014

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Process and Characterization

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