An Analytical Vacuum-Assisted Resin

Transfer Molding (VARTM)

Flow Model

by Bruce K. Fink, Kuang-Ting Hsiao, RoopeshMathur,

John W. Gillespie, Jr., and SureshG. Advani

Approved for public release;distribution is unlimited.

The findings in this report are not to be construed as an official
Department of the Army position unless so designated by other
authorized documents.

Citation of manufacturers or trade names does not constitute an

official endorsement or approval of the use thereof.

Destroy this report when it is no longer needed. Do not return

it to the originator.
Army Research Laboratory
AberdeenProving Ground,MD 2 1005-5069

ARL-TR-2354 October 2000

An Analvtical Vacuum-Assisted Resin

J

Transfer Molding (VARTM) Flow Model

Bruce K. Fink
Weapons and Materials ResearchDirectorate, ARL

Kuang-Ting Hsiao, Roopesh Mathur,

John W. Gillespie, Jr., and Suresh G. Advani
University of Delaware

Aooroved for oubhc release: distribution is unlimited.

Abstract

A closed form solution for the flow of resin in the vacuum-assisted resin transfer
molding (VARTM) process is used extensively for affordable manufacturing of large
composite structures, During VARTM processing, a highly permeable distribution
medium is incorporated into the preform as a surface layer. During infusion, the resin
flows preferentially across the surface, simultaneously through the preform, to a complex
flow front. The analytical solution presented here provides insight into the scaling laws
governing fdl times and resin inlet placement as a function of the properties of the
preform, distribution media, and resin. The formulation assumes that the flow is fully
developed and is divided into two areas: (1) a saturated region with no crossflow, and (2)
a flow front region, which moves with a uniform velocity, where the resin is infiltrating
into the preform from the distribution medium. The law of conservation of mass and
Darcys Law for flow through porous media are applied in each region. The resulting
equations are nondimensionalized and are solved to yield the flow front shape and the
development of the saturated region. It is found that the flow front is parabolic in shape,
and the length of the saturated region is proportional to the square root of the time
elapsed. The obtained results are compared to data from full-scale simulation and show
good agreement. The solution allows greater insight into the physics process, enables
parametric and optimization studies, and can reduce the computational cost of full-scale,
three-dimensional (3-D) simulations.
 Table of Contents

List of Figures .......... .. ......... .......... ...................-........................................................ V

List of Tables ................................ .. ... .. ................................. ......-...-...-..................... vii

1. Introduction .......... ............................. .........-............................................................. 1

2. Problem Statement .............................................................................. ..................... 5

3. Analytical Solution.. ................................................................................................. 11

4. Verification: Full-Scale Simulations ..................................................................... 19

5. Effect of Process Variables: A Parametric Study ....... ......_._................................ 21

5.1 Effect of Thickness Ratios.. ................................................................................. 21

5.2 Effect of Permeability.. ........................................................................................ 23
5.3 Effect of Porosity ................................................................................................. 24

6. Conclusions _.._._.........................................................................................-............... 25

7. References .._...._._.................................................-....-...........-..............................-..-.. 3 1

Distribution List ...._........................-..............Y.......................-...._...._...__................... 33

Report Documentation Page ....._..........._......-.......................................................... 53

. ..
111
INTENTIONALLY LEFT BLANK.

. I

iV
 List of Figures

.* Figure m
1. Examples of the Broad Application Potential for VARTM ProcessesIncluding
. Shipping, Infrastructure, Land Combat Vehicle Armor, and Repair.. .......................

2. Layup of Materials in the VARTM Process ..............................................................

3. Two-Layer Model of Resin Flow in the VARTM Process.. ......................................

4. Schematic of Resin Flow in the Flow Front Region for the Two-Layer
VARTM Model .......................................................................................................... 7

5. Illustration for Resin Mass Balance in the Flow Front Region in the
Two-Layer Model ...................................................................................................... 12

6. Two Mathematical Roots of hF*(X*) = 0.. ................................................................. 17

7. Example of a Full-Scale Numerical Simulation: (a) Flow Front History and

(b) Pressure Distribution at the Final Time Step ....................................................... 22

8. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of Thickness Ratios .......................................................................... 23

9. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of Permeability of Distribution Medium .......................................... 25

10. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of In-Plane Permeability of Fiber Preform ....................................... 26

11. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of Transverse Permeability of Fiber Preform ................................... 27

12. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of Porosity of Distribution Medium ................................................. 28

13. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of Porosity of Fiber Preform.. ........................................................... 29
.

I
bTENTIONALLY LEFT BLANK.

vi
 List of Tables

Table m

1. Comparison of Closed Form Solution With Results From Full-Scale Numerical

l
Solution of the VARTM Process................. ...................................... ................ ......... ... .. 20

vii
INI-ENTIONALLY LEFT BLANK.

. ..
Vlll
 1. Introduction

.
The vacuum-assisted resin transfer molding (VARTM) process offers numerous cost
advantages over traditional RTM via lower tooling costs, room temperature processing, and
scalability to large structures. Recent advanced technology demonstrators such as the Advanced
Enclosed Mast Sensor @EM/S) System and the composite advanced vehicle (CAV) have shown
the potential of VARTM technology for the low-cost fabrication of large-scale structures
requiring thick-section construction and hybrid multifunctional integral armor. The VARTM
process is also used extensively in commercial applications such as bridge decks, rail cars, and
yachts (Figure 1).

Figure 1. Examples of the Broad Application Potential for VARTM Processes Including
Shipping, Infrastructure, Land Combat Vehicle Armor, and Repair.
 VARTM is a composites manufacturing process that involves the layup and vacuum bagging
of dry reinforcing fibers in fabric, tape, or bulk form as a preform in a one-sided open mold and
impregnating the preform with liquid resin using negative pressure (i.e., a vacuum) followed by
cure and demolding. The advantages of the VARTM process over the RTM process are
scalability and affordability for the fabrication of large composite structures. Large parts can be
infused rapidly using vinyl esters, phenolics, and epoxies at room temperature under vacuum
pressure only. Consequently, tooling costs and investments are substantially reduced. VARTM
is a completely closed system that traps volatile organic compounds (VOCs), reduces the need
for solvents, and results in less scrap than other processes.

The present study focuses on Seemanns Resin Infusion Molding Process (SCRIMP)
(Seemann 1990). In this VARTM process, a highly permeable distribution medium is
incorporated into preform as a surface layer. During infusion, the resin flows preferentially
across the surface and simultaneously through the preform thickness enabling large parts to be
fabricated solely under vacuum pressure. The layup of the materials in the process is shown in
Figure 2.

In very large composite structures, multiple inlet gates are required to. ensure complete wet-
out of the part prior to gelation of the resin. Selection of distribution media, performs, and gate
and vent locations are based on past experience for similar applications. New applications in
which part thickness, resin, or preform characteristics change require costly trial and error
process development. Hence, a fundamental understanding of the process physics and associated
models represent a significant contribution to the science base for VARTM.

Modeling and predicting the flow during the impregnation process provides insight into the
process physics and highlights potential problems before production. In addition, flow
prediction enables optimization of the design variables affecting the process, such as the distance
between resin inlets (in the case of multiple lines and thickness of the diffusion layer), and
provides rules of thumb for scaling of the prototypes. Thus, a fundamental understanding of the
underlying science will help develop models to reduce costs, aid in selection of design
parameters, and improve quality.

2
 resin

I fiber preform under vacuum

vacuum

layup detail

vacuum bag

distribution layer

PeeI PiY

Figure 2. Layup of Materials in the VARTM Process.

3
 The flow of resin through porous media such as fiber preforms and resin distribution media is
governed by Darcys Law:

u=- - Ic .VP, (1)

IJ

where u is the Darcys velocity (defined as the total flow rate per total flow front area), K is the
permeability tensor (which characterizes the ease of flow through the fiber perform), and ,LJis
the viscosity of the resin. This, when coupled with the continuity equation for incompressible
flow, gives the Laplace equation for the fluid pressure field inside a region permeated by the
fluid:

(2)

This equation can be discretized using finite element methods which then form the basis for
simulation of mold-filling during the resin infusion process (Bruschke and Advani 1990, 1991a;
Liu et al. 1996; Mohan et al. 1999).

The flow simulations can be either two-dimensional (2-D) or three-dimensional (3-D). In

2-D flow modeling (Bruschke and Advani 1991b; Trochu et al. 1994; Lee et al. 1994), the flow
of resin through the thickness is considered uniform, and the finite element discretization is
applied along the other two directions as with liquid injection molding simulation (LIMS), which
is based on the finite element/control volume approach. In 2-D simulations, only the in-plane
permeabilities are supplied (Simacek et al. 1998). In 3-D simulations, the pressure and flow in
all three directions is solved, and a 3-D permeability sensor is supplied as input, as in the resin
infusion process simulation (FUPS), which is based on finite element methods without the use of
the control volume approach (Gallez and Advani 1996). Usually, the geometry, the material .

parameters, and the position of resin inlets and outlets are specified before the filling simulation
.
is carried out. Simulation codes are used to track flow fronts and estimate the fill times.

4
 Parametric studies then can be conducted with simulations to design the mold and the process
.
parameters.

Closed form analytical solutions have also been derived for the resin flow under simplifying
assumptions and for simple geometries. These solutions explain the role of various process
variables and their interactions during processing. Indeed, a closed form solution of the resin
flow during the VARTM process not only enables parametric studies, optimization, and
reduction of computational expenses of full-scale simulations, but also offers insight on the
scaleup of the process and material parameters for large structures.

In earlier work, Tari et al. (1998) derived a closed form model for vacuum-bag RTM under
several simplifying assumptions. They assumed that the velocity of resin in the fiber preform is
negligible and that the region behind the flow fi-ont is uniformly saturated. In the present work,
these assumptions were not made, so the velocity of the resin, as well as the shape of the flow
front through the thickness of the fiber perform, are accurately captured. This is important for
scaling purposes.

A closed form solution for the flow of resin in the VARTM process is presented here. The
layup is modeled as the distribution layer (high permeability material) and the structural layer
(preform material). It is assumed that the flow is well developed and can be divided into a
saturated region with no crossflow and a flow front region in which the resin infiltrates the
preform from the distribution medium. The flow front region is assumed to be fully developed
with a uniform velocity. The law of conservation of mass and Darcys Law for flow through
porous media are applied in each region. The resulting equations are nondimensionalized and
are solved to yield the flow front shape and the development of the saturated region.

2. Problem Statement

As illustrated in Figure 3, the layup of materials is modeled as two layers of permeable

materials. The distribution layer is much thinner than the structural layer, h, << h, , where h, and

5
 PO: injection Pressure

Layer 1: Distribution Layer ; Flow Front Region

I Layer 2: Structural Layer /Vacuum Pressure( = 0

Note: d - region with transverse flow = flow front length.

D - region without transverse flow = length behind the flow front region.
UF - flow front velocity.
,u - viscosity of resin.

Figure 3. Two-Layer Model of Resin Flow in the VARTM Process.

h,are the respective thicknesses of the two layers. The flow front in the distribution layer is

considered uniform. The permeability of the distribution layer is K,, along the flow direction,

and the permeabilities of the structural layer are K,,and K,, in the x and y directions,

respectively. The constant inlet injection pressure (atmospheric pressure) is PO, and the resin

viscosity is p .

In the saturated region, the flow is one-dimensional (1-D) with Darcys velocities U, and U,
in layers 1 and 2, respectively. The length of this saturated region is D, and the pressure at its
boundary with the second flow region is assumed to be PD.

The second region, illustrated in Figure 4, is the flow fi-ont region where there is transverse
flow from the distribution layer to the structural layer. The flow front region of length d is
assumed to maintain its shape, given by h, , and advances with a uniform horizontal velocity of

6
 Flow Front Region
I

Vacuum Pressure 0
t

Figure 4. Schematic of Resin Flow in the Flow Front Region for the Two-Layer VARTM
Model.

U,. This is the observed velocity of the resin and not the Darcys velocity. The transverse
velocity of resin infiltration from the distribution layer into the structural layer is Q,. The

horizontal velocity in the flow front region in the distribution layer u,, is with boundary

condition u,, (x = D + d) = 0, U, .

Since the resin is an incompressible fluid, using the continuity equation and Darcys Law in
the structural layer, the governing equation for the pressuredistribution is
 K a2p; K a*p-()
2xX
3X2
2YY (3)
?Y :

Consider the following nondimensional variables:

p=$ ,X* =x,y* 2, (4)

c xc YC

where x, and y, are the characteristic length scales in the longitudinal and thickness directions,

respectively, and P, is a scaling parameter for the pressure. Introducing the dimensionless

variables, the governing equation can be recast in dimensionless form as follows (Pillai and
Advani 1998a, 1998b):

K,,yf a*p* + -=
a2p* o
K,,x,Z ax** $2 .
(5)

Since the resin distribution media was used in the process to enable the rapid and uniform
distribution of the resin across the mold surface, it can be assumed that within the flow front
region in the structural layer, the major portion of the resin flow is from the distribution layer
into the structural layer. Hence, the flow rate in the y direction must be more significant than
that in the x direction (i.e., Qy >> Q,). The x, in the flow fi-ont region is d, while y, is h,. If
-
u and v are the averageDarcys velocities in the two directions, then

Qy =id,

and (6)

Q, =;h2.

Considering Darcys equation for the velocities, the following scaling argument can be made:

8
 (7)

and

K2, ap - K2vvp
v= ----&.j,-A (8)
Pay P h2

Since QY >> Q,, from equations 6 to 8, it can be determined that:

K*xxG- << 1
(9)
K,,d*

This allows for the neglect of the x-term in pressure equation 5 in the flow front region, which
leads to the following result:

and

v=---=K2yy ap K2yy
--fA-4
CL@ I-L

At the top of the structural layer, where the flow is always Corn the distribution layer, the
boundary condition is defined as v jyzO=z+*,,(x). Hence, in the flow fi-ont region,
I .

v(x) = Gy (4,

9
where yzY(x) is the velocity of the resin flow from the distribution to the structural layer in the

flow front region. In the saturatedregion, the length scale of the flow is D in the x direction and
h, in the y direction, where D >> h, . Since D >> d, from equation 9,

K2Jc <<la K2A <<l. (11)

K2yyd2 K2,DZ

So, the first term in equation 5 can be neglected, and

Thus, the velocity in they direction in the saturatedregion is

v= ---=-- w
K2yy K2yy
cc fsW (13)
P ay

At the bottom of the structural layer in the saturated region, the resin is in contact with the
surface of the mold, which is impermeable. Hence, the no-penetration boundary condition was
applied (i.e., v = 0 @y = h2) in the saturated region. Therefore,

dP
s = fs (x) = 0 in the saturated region. (14)

As a result, v = 0 in the saturated region everywhere in the structural layer. Since v = 0, the
second term in pressure equation 3 becomes zero, and

$0 spy),
.

10
 as

. -=
ap
@0*
So, it can be inferred that g(y) is constant, and ,

u=---Lx ap (15)
P ax

is constant in the saturated region. Hence, from boundary conditions of P = P, @x = 0 and

P=P,@x= D,

ap pD-po
in the saturatedregion. (16)
dx= D

3. Analytical Solution

Considering the element fluid volumes shown in Figure 5 and invoking the mass balance,

U,zy~+U2(-dhF)=UFQZZ(-dhF)~U**y =*(@*uF -u,). (17)

A lumped mass balance in the distribution layer in the flow front region gives

-du,,h, = ~,~,,dx3 u,~,, = -h, - (18)

di-
.

11
Figure 5. Illustration for Resin Mass Balance in the Flow Front Region in the Two-Layer
Model.

From equations17 and 18,the resultis

%, = -h h?x
d = $q@2uF -4,).
Ix (19)

ApplyingDarcys Law in they direction in the flow front regionandusingequations17 and

18,

and

12
This leads to the following equation for 4 (x) , the pressure field in the distribution medium in
the flow front region:

&*)=h,~(@,u, -u2+ (21)

2YY

A similar mass balance in the flow front region, including both the structural and the distribution
layers, yields

U,h, +U,h, =U,(@, h, +@ 2 h,). (22)

Applying Darcys Law in the saturated region with 1-D flow,

and (23)

PO- PLI3 K
u, =-K2, u, =u,x.
P D K 2xX

In combination with equation 22,

(24)

The previous set of equations can be nondimensionalized using the following nondimensional
variables:

13
 h; +x* =- x-D (25)
2 h2

and

4*=$I* =$,p* =$ -
2 2 0

This gives the following system of equations:

(26)

(27)

(28)

and

(29)
-

Here, p* = -ti2UF is obtained from the nondimensional Darcys Law. The boundary conditions
KLJO

14
on UT, are Use= U,*.U~:(~*)= $1. The boundary conditions on h; (0) = l,h; (d ) = 0. The

pressureboundary conditions are <* (0) = Pi,c* (d )= 0.

Integrating equation 29 and applying the boundary condition ulx (0) = U,*,U;, (d ) = @I,

In combination with equation 26,

dl?
1=
dx*
-CL
tt
Ulx = cc
a
h; (x )+ @, .
1 (31)

Combining equations 29 and 3 1, the following nonlinear ODE with boundary conditions
hi (0) = 1,hi (d * ) = 0 result in:

,;;1. . (32)
2 2

This ODE is of the form given by (y2) = ay + b. It can be solved using the substitution
dY
p=d,,y.=pdp dy (Murphy 19W This usually yields a solution in a quadratic form.
The quadratic form hi (x ) = ax2 + /3x* + y can be substituted into the above equation to find the

solution using the first boundary condition hi (0) = 1 and matching the coefficients of the powers

of x* on either side. Then the second boundary condition, hi(d*) = 0, can be used to determine

d * . This gives a quadratic equation for d * having two roots. Both roots are positive, but if the
larger one were chosen, then the flow front profile would be physically impossible (Figure 6).
Hence, the smaller root gives the following unique solution:

15
 K*2YY
a=-
6h,*

(33)

and

y=l.

Thus,

K* *2
h;(n)=--$, (34)
1

and since hi (d ) = 0, d * can be determined as

(35)

Substituting the form h;(x*) = ax** + /3x* + y in equation 29, the pressure can be
determined as follows:

p = -b2 -dJ*
1
[2ax* + 3a/?x + (p + 2a)x* + pl (36)
K 7-YY

Applying the boundary condition 4 (0) = Pi gives

16
 --
\
Xf = d* Nonphysical Region

Flow Front Shape: &(x*)

Figure 6. Two Mathematical Roots of hi* = 0. Note That Only the Smaller Root Is
Physically Possible.

(37)

Using the nondimensional form of Darcys Equation in the saturatedregion,

u* =--s
G, 1-p; *---.=1--p
P* l o2 -u; G, + w;,
U;D
2
p* D* K 2xX K%Y 3h; @2-u; -

To find Uisubstituted with p* is

--
@2UF _ 1 (38)
* = KlxxPo rLY+A

17
where

r=- u;
K*2.w

and

From equation 38, the flow fi-ont velocity is

&,& 1
Q- -- @, 170*+/c

D
but U, =$, and D = - ; hence, the previous equation becomes
h2

dD Klx,Po 1
-- (41)
-z- ph, ID-+-Ah, -

Solving the resulting differential equation for D(t),

t-t, =C,(D-D)+C,(D-D,) , (42)

where C, = rkf a,ndC,=- The variable t, is the time it takes for the flow front
=Lpo Kl&
region to become fully developed, while D, is the entry length for the development of the flow

front region. Solving for D(t),

18
 (/1h*)Z
+2;pp (t-to+C,D,2
+C*D,)-Ah,
Ixr 0
D(t) = (43)
l-

Equations 42 and 43 are important for the design of the VARTM process. The results
obtained are compared to full-scale, finite-element-based simulations using LIMS 4.0 and are
presented in the next section. A parametric study is presentedto shed light on how one can scale
the parametersin the VARTM process.

4. Verification: Full-Scale Simulations

The results obtained can be compared to finite-element-based simulations of the filling

process in VARTM. LIMS 4.0 was used for simulation of the tilling process for five different
cases,with different values for permeabilities and fiber volume fractions for the distribution and
structural layers, respectively, and length of part, D. Each part was modeled using finite
elements and the filling process simulated as a constant pressure injection at 1 atm at one comer
of the part. The viscosity of the resin, the thicknesses of the structural and distribution layers,
and the permeability of the distribution layer were held constant. The fill times and the values of
d were determined and compared to those obtained from the closed form solution. The results
are tabulated in Table 1. The fill time from the analytical solution was found to be within 2% of
the value from the full-scale numerical simulation, while the value of d was within 12% of the
value from simulation. For all cases, the condition K2,h-i << 1-.was maintained for a valid
K*,d2
analytical solution.

The flow front history and the pressure contours at the final time are plotted for Case 1 in
Figure 7. It can be observed that the flow front is constant in shape, while the lines of constant
pressure in the saturated region are equally spaced and vertical to the x axis, thus verifying the
assumptions of constant flow front shape and linear variation in pressure in the saturatedregion.

19
Table 1. Comparison of Closed Form Solution With Results From Full-Scale Numerical
Solution of the VARTM Process

t-to % Error
(s)

LIMS 4.0 Closed Form Closed Form

hse Parameters
Solution LIMS 4.0 Solution d
(%) (i)
1 Kzxx= 8.8E-7 cm 2 8.9 9.8 44.9 44.8 9.7 -0.3
Kz~ = 4.4E-7 cm2
01= 0.99, $2 = 0.50
D-Do = 40.0 cm
2 K2xx= 8.8E-7 cm2 29.2 30.9 19.1 19.4 5.7 1.5
K2yy= 4.4E-8 cm2
$1 = 0.99, $2 = 0.50
D-Do = 19.0 cm
3 Kzxx= 8.8E-7 cm 2 3.0 3.1 54.2 54.5 2.9 0.5
K2, = 4.4E-6 cm2
$1 = o-99,+2 = 0.50
D-Do = 47.0 cm
4 Kzxx= 8.8E-7 cm 2 9.2 10.1 71.7 72.1 10.2 0.6
Kzfl = 4.4E-7 cm2
4, = 0.99, @2= 0.80
D-Do = 40.3 cm
5 Kzxx= 8.8E-7 cm2 9.0 10.0 44.2 44.5 11.6 0.7
Kzyy= 4.4E-7 cm2
0, = 0.70, $2 = 0.50
D-Do = 40.0 cm
jte: The following variables were used in all cases:
PO= lE6 g/cm-s2,
p = 1 g/cm-s
h, = 0.01 cm,
h2=1cm,
Klxx = IE-3 cm2, and
Do-O cm for all the cases.
a Based on results from LIMS 4.0.

20
 5. Effect of Process Variables: A Parametric Study

The process variables that affect the flow of resin are broadly classified into geometric
parameters (such as thickness) and material properties (such as permeability and porosity of the
two layers). These process variables influence the time to fill a mold of a given length. A
parametric study of these effects allows for better design and analysis of the VARTM
manufacturing process. In the present section, the effect of a number of process variables on the
fill times and flow velocity was studied. The baseline values used for the study are:

P, =latm,p=lcp,
h, = 1.00 cm, h, = 0.025 cm,
K ,xx =8.8x10-4cm2,K,, = 8.8x10-cm,K,, =1.47x10-cm, and
a, = 0.99, cp, = 0.50.

In the plots for each parameter, the flow front velocity (UF) and the time taken (t) are plotted
against D for different values of the parameter. Note that the time axis is reversed; therefore, the
lines for t start from zero at the top of the graph.

5.1 Effect of Thickness Ratios. The effect of the ratio of the thickness of the distribution
medium to that of the structural layer, hJ = + , is considered. Figure 8 plots the flow front
velocity, U,, vs. D for different thickness ritios. As h, increases, the flow front velocity
increases while the fill time decreases for a given length D. This is because as the thickness of
the highly permeable distribution medium relative to that of the structural layer increases, the
resin flow rate in the distribution medium increases. Since the diffusion material is used to
distribute resin in the part and ensure mold filling, an increase in h,* will cause an increase in
flow front velocity and a decreasein fill time.

For the case of h; = 0.1, encountered with thin section composite parts, U, shows a slower

decrease with D than with the other cases. With thick-section composite parts where h, + 0,

21
 0.1

-0.1

-0.2

-0.3

-0.4

-0.5

-0.6

-0.7

-0.8

-0.9

-1

(a) Flow Front History

0.1

-0.1

-0.2

-0.3

,-0.4

% -0.5

-0.6

-0.7

-0.8

-0.9

-1 -I -I t
0

(b) Pressure Distribution at the Final Time Step

Figure 7. Example of a Full-Scale Numerical Simulation: (a) Flow Front History and
(b) Pressure Distribution at the Final Time Step.

22
 0

* 8
\

. 7

6 \
-+--UF(h,/h2=0.1)
--i- -UF(h,/h2=0.025)
-t -UF(hl/hz=0.00625)
-t- t-t0(h,/h2=0.1)
-f- t-to(h,/h2=0.025)
et-t0(h,/hz=0.00625) 1500

2000

2500
0 50 100 150 200 250

Wm)

Figure 8. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of Thickness Ratios.

U, falls rapidly. In order to fill such a part efficiently, the distance between the gates (0) has to
be small; thus, the number of gates required increases. Therefore, the solution provides insight
into the scaling laws required for manufacturing thick-section composites by VARTM.

5.2 Effect of Permeability. The permeability values of importance are: ICI*,, the
permeability of the distribution layer in the longitudinal x direction, and K;, and Klw, the
permeabilities of the structural layer in the longitudinal x and thickness y directions. As seen in

23
Figures 9-l 1, as the permeability values increase, the time to fill decreases,and the flow front
velocity increases. As the permeability values increase, the resistance of the material to the resin
flow decreases. Hence, the net flow rates are higher, and the time to till decreases, while the
flow front velocity increases. Since the flow rate in the distribution layer is higher, the effect of
K,*, is significantly more than that of K;, and Ki, . These effects can also be observed from
the plots shown. This has important ramifications on the selection and the thickness of
distribution media.

5.3 Effect of Porosity. The porosity of a fiber preform is defined as the fraction of the total
volume of the material not occupied by the fibers. In composite manufacturing, the
complementary term, volume fraction, was more commonly used. The volume fraction is
defined as the fraction of the fiber preform occupied by the fibers and is related to the porosity
by the relation V/ = 1- CD. The porosity also affects the permeability of the material. However,

this coupling has not been accounted for in the present work.

The porosity values considered here are CD,,the porosity of the distribution layer, and cD~,

the porosity of the structural layer. As observed from Figure 12, 0, did not significantly affect

the time to fill and the flow front velocity. In Figure 13, as Oz increases, the flow-front velocity
decreases,and the fill time significantly increases. This is because the fraction of the total part
volume occupied by the thin layer of diffusion material is very low compared to that occupied by
the fiber preform in the structural layer. Hence, increasing the porosity of the diffusion material
does not have a significant effect. Whereas, if cD~increases, the volume of the structural layer
(which is unoccupied by the fiber perform) significantly increases. This additional volume must
be filled by the resin, thus requiring more time to fill it and therefore slowing down the flow
front.

24
 9

7
1000

t -+- ~.
I UF (K,,, = 3.52E-3cm*)
\ * 1500.
\ ~ t-b (I&, = 2.2E-4cm*) 3z
M
t-h (I& = 8.8E-4cin*)
\-
\ t-b (I& = 3.52E-3cm*)
2000
i \
?
a
4 +c
2500

3000
0 50 100 150 200 250

Wm)

Figure 9. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of Permeability of Distribution Medium.

6. Conclusions
.
A closed form solution for flow of resin in the VARTM process has been developed. This
process is explained by a two-layer model comprised of a distribution layer and a structural
layer, containing fiber preform. The flow is divided into a saturated region where there is no

25
 6

P i - -+ - Ur (IQ,, = 5SE-8 cm2)

--A- - Ur (I& = 8.8E-7 cm2)
5 3 s
-+ - Ur (I& = 3.52E-6 cm2)
k
5
2

0
0 50 100 150 200 250
Wcm)

Figure 10. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of In-Plane Permeability of Fiber Preform,

crossflow, and a flow front region with a steady shape and uniform velocity where the driving
flow emanates from the distribution layer to the structural layer. It is assumed that the thickness
of the distribution layer is much smaller than that of the structural layer, and that the length of
the flow front region is much smaller than that of the saturated region. It is also assumed that the
crossflow in the flow front region is much higher than the flow from the saturatedregion into the
flow front region. Darcys Law regarding flow in porous media and mass balances at different
sections was used to formulate a system of differential equations, and a closed form solution was

26
 100

200

300

,
400
zE 3
I
\ z
= 2.5 4 -+--UF (lC& = 9.1875E-9 cm2)
500 =
5 4 - +--UF (I&, = 3.675E-8 cm2)
2 600
A - * -uF (Kzyy = 1.47E-7 cm2)
\ \
-t-b (I&,, = 9.1875E-9 cm2) 700
1.5 $4 \
\, \, et-t, (K2,,,,= 3.675E-8 cm2)
1 800

0.5 900

0 1000
50 100 150 200 250
D (cm)

Figure 11. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of Transverse Permeability of Fiber Preform.

found. The model predicted the shape and development of the flow front given the material
properties, the geometric parameters, the pressure at the inlet, and the viscosity. The obtained
results were verified by comparing them with full-scale simulations. The parametric study
indicated trends that reflect the physics of the flow process and identified the parameters that

27
 100

200
3.5

300

400 z
-t- UF (porosity = 0.6) w
- i- - UF (porosity = 0.7)
- *- - UF (porosity = 0.8) 500
-t-b (porosity = 0.6)
1.5 + t-b (porosity = 0.7)
-t-t-b (porosity = 0.8) 600
1

0.5

0 800
0 50 100 150 200 250
D @ml

Figure 12. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of Porosity of Distribution Medium.

significantly affect the filling process. Subsquent solutions provided physical insight into the
manufacturing process and can be used for scaling, design, and optimization of the VARTM
process.

28
 8
.

- +- -UF (porosity = 0.3) 400 z

c,
- -A- -UF (porosity = 0.4)
-t -UF (porosity = 0.5)
500
.+ t-b (porosity = 0.3)
+ t-b (porosity = 0.4)
2 -)- t-b (porosity = 0.5) 600

0 800
0 50 100 150 200 250.
D (cm)

Figure 13. Flow Front Velocity and Fill Time as a Function of Length of the Saturated
Region: Effect of Porosity of Fiber Preform.

29
INTENTIONALLYLEFTBLANK.

. I

30
 7. References

Bruschke, M. V., and S. G. Advani. A Finite Element/Control Volume Approach to Mold

Filling in Anisotropic Porous Media. Polymer Composites, vol. 11, pp. 398-405, 1990.

Bruschke, M. V., and S. G. Advani. A Numerical Approach to Model Non-Isothermal, Viscous

Flow With Free Surfaces Through Fibrous Media. International Journal of Numerical
Methods in Fluids, vol. 19, pp. 575-603, 1991a.

Bruschke, M. V., and S. G. Advani. RTM: Filling Simulation of Complex

Three-Dimensional Shell-Like Structures. SAMPE Quarterly, vol. 3, no. 1, pp- 2-l 1,
1991b.

Gallez, X. E., and S. G. Advani. Numerical Simulations for Impregnation of Fiber Preforms in
Composites Manufacturing. Proceedings of the Fourth International Conference on Flow
Processesin Composite Materials, University of Wales, 1996.

Lee L. J., W. B. Young, and R. J. Lin. Mold Filling and Cure Modeling of RTM and SCRlMP
Processes. Composite Structures, vol. 27, pp. 1-2, 1994.

Liu, D., S. Bickerton, and S. G. Advani. Modeling and Simulation of RTM: Gate Control,
Venting and Dry Spot Prediction. Composites Part A, vol. 27A, pp. 135-141, 1996.

Mohan, R. V., N. D. Ngo, and K. K. Tamma. On a Pure Finite Element Based Methodology for
Resin Transfer Mold Filling Simulations. Polymer and Engineering Science, vol. 39, no. 1,
pp. 2843,1999.

Murphy, G. M. Ordinary Dz@rential Equations and Their Solutions. Princeton, NJ: Van
Nostrand, 1960.

Pillai, K. M., and S. G. Advani. Numerical Simulation of Unsaturated Flow in Woven or

Stitched Fiber Mats in Resin Transfer Molding. Polymer Composites, vol. 19, no. 1,
pp. 71-80,1998a.

Pillai, K. M., and S. G. Advani. A Model for Unsaturated Flow in Woven or Stitched Fiber
Mats in Resin Transfer Molding. Journal of Composite Materials, vol. 32, no. 19,
pp. 1753-1783,1998b.

Seemann, W. H., II. Plastic Transfer Molding Techniques for the Production of Fiber
Reinforced Plastic Structures. U.S. Patent 4,902,2 15, 1990.

Simacek, P., E. M. Sozer, and S. G. Advani. User Manual for DRAPE 1.l and LIMS 4.0.
Technical Report 98-01, Center for Composite Materials, University of Delaware, 1998.

31
Tari, M. J., J. P. Irnbert, M. Y. Lin, A. S. Lavine, and H. T. Hahn. Analysis of Resin Transfer
Molding With High Permeability Layers. Journal of Manufacturing Science and
Engineering, vol. 120, pp- 609-616, 1998.

Trochu, F., R. Gauvin, D. M. Gao, and J. F. Boudreault. RTMFLOT-An Integrated Software

Environment for the Computer Simulation of the Resin Transfer Molding Process. Journal
of Reinforced PIastics and Composites, vol. 13, no. 3, pp. 262-270, 1994.

. I

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106 DIR USARL AMSRL WM MA

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A MARK P MOY
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M ADAMSON G RODRIGUEZ
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A HORST K BOYD
E SCHMIDT S CORNELISON
AMSRL WM BA P DEHMER
F BRANDON R DOOLEY
AMSRL WM BC W DRYSDALE
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G HAGNAUER AMRSL WM MC
J MCCAULEY J BEATTY
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AMSRL WM MD
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S WALSH
AMSRL WM T
B BURNS
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J RUNYEON
M BUTUUNS
E HORWATH
B GOOCH
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 .

52
 Form Approved
REPORT DOCUMENTATION PAGE OMB No. 07060188

Public reporting burden for *his ccAleRion of infomution is esfimated to avenge 1 hour per response, includmg the time for reviewing InStruCtions. searching existing data Sources,
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1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE 3. REPORT NPE AND DATES COVERED

October 2000 Final, January 1997-July 1999

4. TITLE AND SUBTITLE 5. FUNDING NUMBERS
An Analytical Vacuum-Assisted Resin Transfer Molding (VARTM) Flow Model 62105AH84

6. AUTHOR(S)
Bruce K. Fink, Kuang-Ting Hsiao,* Roopesh Mathur; John W. Gillespie, Jr.,*
and Suresh G. Advani*

7. PERFORMING ORGANlZATlON NAME(S) AND ADDRESS 6. PERFORMING ORGANIZATION

U.S. Army Research Laboratory REPORT NUMBER

ATTN: AMSRL-WM-MB
Aberdeen Proving Ground, MD 21005-5069 ARL-TR-2354

9. SPONSORING/MONITORING AGENCY NAMES(S) AND ADDRESS 10.SPONSORING/MONlTORlNG

AGENCY REPORT NUMBER

11. SUPPLEMENTARY NOTES

l University of Delaware, Newark, DE 197 16

12a. DISTRIBUTlON/AVAlLABlLlN STATEMENT 12b. DISTRIBUTION CODE

Approved for public release; distribution is unlimited.

13. ASSTRACT(Maximum 200 words)

A closed form solution for the flow of resin in the vacuum-assisted resin transfer molding (VARTM) process is used
extensively for affordable manufacturing of large composite structures. During VARTM processing, a highly permeable
distribution medium is incorporated into the preform as a surface layer. During infusion, the resin flows preferentially
across the surface, simultaneously through the preform, to a complex flow front. The analytical solution presented here
provides insight into the scaling laws goveming fill times and resin inlet placement as a function of the properties of the
preform, distribution media, and resin. The formulation assumes that the flow is fully developed and is divided into two
areas: (1) a saturated region with no crossflow, and (2) a flow front region, which moves with a uniform velocity, where
the resin is infiltrating into the preform from the distribution medium. The law of conservation of mass and Darcys Law
for flow through porous media are applied in each region. The resulting equations are nondimensionalized and are
solved to yield the flow front shape and the development of the saturated region. It is found that the flow front is
parabolic in shape, and the length of the saturated region is proportional to the square root of the time elapsed. The
obtained results are compared to data from full-scale simulation and show good agreement. The solution allows greater
insight into the physics process, enables parametric and optimization studies, and can reduce the computational cost of
full-scale, three-dimensional (3-D) simulations.
14. SUBJECT TERMS 15. NUMBER OF PAGES

composite material, vacuum-assisted resin transfer molding, flow modeling

16. PRICE CODE

17. SECURIN CLASSIFICATION 18. SECURIN CLASSIFICATION 19. stxuRirY CLASSIFICATION 20. LIMITATION OF ABSTRACT
OF REPORT OF THIS PAGE OF ABSTRACT
UNCLASSIFIED UNCLASSIFIED UNCLASSIFIED UL
NSN 7540-01-280-5500 Standard Form 298 (Rev. 2-89)
53 Prescribed by ANSI Std. 239-l 8 298-l 02
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54
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