A Seminar Report on

“VACUUM ASSISTED RESIN TRANSFER MOULDING”

Submitted to the Department of Mechanical Engineering
In Partial Fulfillment of the Requirement for the Degree of

BACHELOR OF TECHNOLOGY
MECHANICAL ENGINEERING

: Prepared by
Mr. PAWAN SHARMA
(Roll No. U13ME210)
B. TECH. IV (M) 7th Semester

: Guided By :
Prof. D. B. GOHIL
Mechanical Engg. Department

(Year : 2016-17)
DEPARTMENT OF MECHANICAL ENGINEERING
Sardar Vallabhbhai National Institute of Technology
Surat-395007, Gujarat, INDIA.
 Sardar Vallabhbhai National Institute of Technology
Surat-395007, Gujarat, INDIA.

MECHANICAL ENGINEERING DEPARTMENT

This is to certify that the SEMINAR REPORT entitled “Vaccum Assisted Resin
Transfer Moluding” is presented & submitted by a student Mr. Pawan Sharma, bearing
Roll No. U13ME210,of B.Tech. IV, 7th Semester in the partial fulfillment of the
requirement for the award of B.Tech. degree in Mechanical Engineering.

He has successfully and satisfactorily completed his Seminar Exam in all respect. We,
certify that the work is comprehensive, complete and fit for evaluation.

Prof. D. B. GOHIL
Seminar Guide
Dr. H.J.Nagrasheth
Head, MED
EXAMINERS:
Date: …………………………………
Name Signature
1.____________________ __________________

2.____________________ __________________
3.____________________ __________________
 ACKNOWLEDGEMENT

It gives me great pleasure to present my seminar report on “Vaccum Assisted Resin Transfer
Moulding process ". I would like to express my deep sense of gratitude to my Seminar
Guide Prof. D. B. Gohil, Mechanical Engineering Department, Sardar Vallabhbhai National
Institute of technology, Surat for his valuable guidance, useful comments and support to my
seminar.
I am also thankful to Dr. H. J Nagarsheth, Head of the Department, Mechanical Engineering,
Sardar Vallabhbhai National Institute of technology, Surat for providing me the opportunity
to present my seminar.

PAWAN SHARMA
U13ME210

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 ABSTRACT

Vacuum Assisted Resin Transfer Moulding process is one of the latest research topic in this era
of technology. This process provides many benefits like large production can be done,
complex design can be manufactured, good surface finish will achieved . Due to their
advantages this process is used in manufacturing wind turbine, transportation, marine
infrastructure, aerospace technology.

This seminar report gives an overview on Vacuum Assisted Resin Transfer Moulding process,
description of moulding process along with their types. Efforts are made to explain basic set
–up, different types and characteristics of reinforcement and resin used in this process
.Whole procedure of this VARTM process is explained step by step in this report.
Advantages and disadvantages of VARTM process are also explained in brief. . The report is
divided into eight chapters each describing differently but related aspects of the topic so as
to present a good knowledge of VARTM process.

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 CONTENTS

PAGE NO.

ACKNOWLEDGEMENT…………………………………………………..………….…i

ABSTRACT……………………………………………………………….……………...ii

CONTENTS………………………………………………………………………….…..iii

LIST OF FIGURES………………………………………………………………….…...iv

1. INTRODUCTION……………………………………………………………….….….1

2. COMPOSITE MANUFACTURING TECHQIUNES………………………………....3

3. BASIC SET-UP OF VARTM………………………………………………………..…6

4. PRINCIPLE & WORKING………………………………………………………….....8

5. TYPES OF REINFORCEMENT……………………………………………………...11

6. ADVANTEGES AND DISADVANTAGES……………………………………….....16

7. INDUSTRIES USING VARTM…………………………………………...……….…19

CONCLUSION……………………..................................................................................21

REFRENCES…………………………………………………………………………….22

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 LIST OF FIGURES

PAGE NO.

FIGURE 2.1- VARTM mould assembly…………………………………………………….....8

FIGURE 2.2- Effect of pressure on compaction in VARTM…………………………….…….9

FIGURE 3.1- Schematic set-up of VARTM…………………………………………………..11

FIGURE 4.1- Prepared mold……………………………………………………………….….13

FIGURE 4.2- Vaccum and Resin lines…………………………………………………….…..13

FIGURE 4.3-Vaccum bag……………………………………………………………….….…13

FIGURE 4.4- Set-up of VARTM process……………………………………………….…….14

FIGURE 5.1- Types of fibers………………………………………………………………….16

FIGURE 5.2- Comparison of Tensile strength of fibers………………………………………18

FIGURE 8.1- Industries using VARTM process………………………………………………22

FIGURE 8.2- Products made by using VARTM process……………………………………...23

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 CHAPTER-1
INTRODUCTION

1.1 Overview of VARTM

VARTM is a composite manufacturing process to produce high quality large scale components.
In this process, dry perform fabrics are placed in an open mould and a plastic vaccum bag is
placed on the top of the mould. The one sided mould is connected with a resin source and
other with vaccum pump. The liquid resin infuses into the reinforcing, fibres, thanks to the
vaccum drawn through the mould. Curing and de-moulding steps follow the impregnation
process to finish the product. Vaccum assisted resin transfer moulding process has the
potential advantage of relatively low cost with sufficiently high volume fractions of
reinforcement and the process can be readily applied to large scale structures. VRATM is an
infusion process where vaccum draw resin into a one sided mould. A cover, either rigid or
flexible, is placed over the top to from a vaccum tight seal .However, for many aircraft
application. VARTM does not currently provide sufficient repeatability or control of
variability. This unpredictable variability is commonly observed when processing with the
traditional VARTM. In order to produce VARTM parts of aircraft quality on a routine basis,
the variability must be understood.

1.2 Motivation
This process offers the benefit of not requiring an expensive autoclave while also being capable
of producing large, complex aerospace-grade parts. Products produced using this method
vary widely in their application with parts being used in transportation, wind energy, marine,
infrastructure, and aerospace applications. The process’s ability to create large and complex
parts has allowed it to effectively reduce manufacturing costs when utilized to produce parts
that are traditionally constructed of numerous small components.

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1.3 Organisation of the report
Chapter-1-In this chapter, brief introduction of Vaccum Assisted Resin Transfer Moulding
process is given.

Chapter-2-Second chapter deals with Composite manufacturing techniques .In which we are
going to discuss different types of moulding like Transfer Moulding, Rresin Transfer
Moulding, VARTM.
Chapter-3-In third chapter brief introduction of basic set –up of VARTM is given with
schematic diagram.

Chapter-4-This chapter deals with principle and working along with the procedure of VARTM
process.
Chapter-5-In this chapter we deals with the different types of reinforcement , its function and
its characteristics .
Chapter-6-In this chapter we discussed advantages and disadvantages of VARTM process.

Chapter-7-In this chapter we have given some brief information about the industries using
VARTM process and its products.

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 CHAPTER-2
COMPOSITE MANUFACTURING TECHNIQUES

Moulding
Moulding consists of all operations necessary to prepare a mould for receiving molten metal.
Moulding usually involves placing a moulding aggregate around a pattern held with a supporting
frame, withdrawing the pattern to leave the mould cavity, setting the cores in the mould cavity
and finishing and closing the mould. Moulding is the process of manufacturing by shaping
pliable raw material using a rigid frame or model called a pattern. A mould or mould is a
hollowed-out block that is filled with a liquid like plastic ,glass ,metal, or ceramic raw materials.
The liquid hardens or sets inside the mould, adopting its shape. It is traditionally made from solid
milled wood or plaster but may be made from plastic or reformed wood. In classical architecture
and sculpture, the moulding is often carved in marble or other stones.

2.1 Transfer moulding

Transfer moulding , like compression, moulding is a process where the amount of moulding
material (usually a thermoset plastic) is measured and inserted before the moulding takes
place. The moulding material is preheated and loaded into chamber known as the Pot. A
plunger is then used to force the material from the pot through channels known as sprue and
runner system into the mould cavities. The mould remains closed as material is inserted and
is opened to release the part from the sprue and runner. The mould walls are heated to a
temperature above the melting point of the mould material, this allows a faster flow of
material through the cavities.

2.2 Resin transfer moulding

In RTM the resin is injected or drawn into a mould, which contains the fibres, from a
homogeniser under low pressure. The mould can be made from composites for low production
cycles or with aluminium or steel for larger production. The differences between the two types
being that metal has better heat transfer, hence quicker cycle times; metal lasts longer and
deforms less, but at a higher cost. The main problem with this production route is that air can be
trapped in mould and hence a method must be incorporated for allowing this air to escape. A

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number of solutions to the problem exist including extending one level of reinforcement beyond
the cavity (with a 25% resin loss), appropriate vents and creating a vacuum in the mould (which
also improves quality). Large structure, better properties(less movement of fibers), increased
flexibility of the design and lower cost are some of the advantage this process has over
compression moulding mainly due to low pressure injection. Other benefits include rapid
manufacture, not labour intensive, ability to vary reinforcements easily or include cores such as
foam and produce low and high quality products.

2.3 Vaccum assisted resin transfer moulding

VARTM technique comprises from tow basic steps. First sufficient dry reinforcement is placed
onto the surface of the substrate so to meet the structural requirements and second a curable
resin is introduced such that the reinforcement is impregnated and the resin is solidified.
VARTM is used widely as an alternative to open moulding techniques to produce large
components. VARTM employs a single mould tool ,with the reinforcement enclosed by
membrane sealed on to the mould to close the cavity. A distribution medium with a high in
plane permeability is usually placed on the top of the reinforcement to accelerate the in
plane flow. Air is extracted from cavity and the atmosphere pressure outside the bag
compressor the reinforcement onto the mould ,and the resin is then drawn into the mould.

Figure 2.1 VARTM mould assembly.

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The flexibility of the vaccum bag introduces a novel aspect not present in RTM the fluid pressure
field that induces flow also modifies the local compaction state of the reinforcement and
ultimately alters permeability. As fluid pressure changes due to the movement of the flow front,
so does the compaction pressure on the reinforcement which leads to variations in permeability.
This is illustrated in figure 2.2.

Figure. 2.2 Effect of fluid pressure on compaction in VARTM.

Figure 2.2 Effect of pressure on compaction in VARTM

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 CHAPTER-3
BASIC EQUIPMENTS

3.1 The Basic Necessities Are:

1. Any “dry fiber reinforcement”
2. Any low viscosity plastic “resin”
3. A vacuum pump and bag.
4. A plastic injection or porting system.
5. A one-sided mould of the part.
6. A porous transfer material to help the resin travel across the mould surface.
7. For high-quality products software that is designed to open and close the injection or porting
system based on sensor feedback throughout the model.

3.2 VARTM Set-up

When preparing to experiment with infusion, it is important to understand some general concepts
about how materials are used and arranged .Keep in mind that every project is unique and
this guide is not intended to provide the only available options .We will discuss some
variations later. First, the general sequence of events that comprises vacuum infusion is
illustrated in the following diagram. For the purpose of this brochure, we will be focusing on
one general set-up idea with the notion that resin will be infused into a center point in the
laminate .From there ,resin will be pulled outward via vacuum pressure .The final
arrangement of materials should look something like this.

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 Figure 3.1

Figure 3.1 Schematic set-up of VARTM

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 CHAPTER-4
PRINCIPLE AND WORKING

In this chapter we are going to discuss about the principle and working of VARTM process.
1. Dry fabric is “laid up” on one-sided mould
2. A transfer material that allows for easy travel of resin over the side of the cloth opposite of the
mould, (Resin Distribution medium).
3. A vacuum bag is then attached to the opposite surface of the fabric on the other side of the
mould.
4. The air is evacuated with the use of a vacuum pump. When the air is gone the resin from an
external reservoir is drawn into the component by the vacuum pump.
5. The resin in its liquid state is forced into the component with the vacuum.
6. The part is allowed to cure, or the part is cured with a UV catalyst

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Procedure
Step 1: The Mold
Prepare your mold
Select your reinforcement
Select your flow media and/or core material

Figure-4.1 mold
Step 2: Resin and Vacuum Lines
Select your resin feed lines Select your vacuum lines

Figure- 4.2 Vaccum and resin lines

Step 3: Vacuum Bag
Build your vacuum bag
Allow for prohibiting resin from entering the vacuum

Figure-4.3 Vaccum bag

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Step 4: Vacuum Pump
Attach the pump Ensure proper vacuum.
Step 5: Prepare for Infusion
Select your resin bucket set-up
Step 6: Resin Infusion
Catalyze your resin and allow it to start infusing Clamp off resin line.

Figure-4.4 Set-up of VARTM.

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 CHAPTER-5
TYPES OF REINFORCEMENT AND IT’S FUNCTION

Primary:
Resists tensile stresses due to loads acting on the structure
Types
1. Continuous and long fibres.
2. Mesh or grid.
3. Pre-stressed strand.
4. Post-tensioning strand.
Secondary:
Controls cracks which may occur due to shrinkage or thermal loading on the surface.
Types
1. Chopped fibers
2. Carbon Nanotubes to avoid spring – in phenomenon during resin cure.

5.1 Issues with Reinforcing Material

1. Steel rusts, even epoxy coated, galvanized & (metal matrix fibre composites) MMFX.
2. Stainless steel is expensive.
3. Fiberglass is not as efficient as steel or carbon fiber and may degrade.
4. Carbon fiber has traditionally been very expensive

5.2 Chopped Fibers (does not take tensile load):

Basically used to increase the isotropic behavior of the composite
1Cannot be relied on for structural loading.
2 Not reliable for crack control for service conditions.

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5.3 What is a Fiber Resin Mixture?
Fibers + Resin = Fiber Resin Mixture = Composite
Where fiber is the reinforcing material and resin is the matrix material which holds the fiber in a
proper direction. The resins can be of two types thermosetting & thermoplastics but in VARTM
thermoplastics are commonly used due to low viscosity and low permeability which are
important parameters during infusion and the flow of resin through the perform or fiber bed.

5.3.1 Fibers :-
1. Carbon
2. Fiberglass
3. Aramid

Carbon Fiberglass Aramid

Figure 5.1-Types of fiber

5.3.1.1 Characteristics of Carbon Fibers:

1. Very high strength and stiffness
2. Relatively low ultimate strain.
3. Low coefficient of thermal expansion.
4. Thermally stable up to 3500ºF.
5. Excellent moisture and chemical resistance.
6. Electrically conductive and relatively low thermal conductivity.

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5.3.1.2 Fiberglass composite main properties
1. Resistance to corrosive attacks;

2. Tight structure;
3. Superior shock and wear resistance;
4. Lightweight;
5. Simple assembling;
6. Cheap maintenance in service;
7. Low electrical conductivity;
8. Damage and breakage resistance

5.3.1.3 Aramid Fiber Characteristics

1. No melting point.
2. Low flammability.
3. Good fabric integrity at elevated temperatures.
4. Para-aramid fibers, which have a slightly different molecular structure, also provide
outstanding strength-to-weight properties, high tenacity and high modulus.

5.3.2 Resins:
1. Epoxy
2. Polyester
3. Vinylester
4. PVC
5. Polypropylene
6. Polyurethane
7. Phenolic

5.3.2.1 Working of resin

1. Holds the fibers in alignment.
2. Protects the fibers from damage.
3. Transfers stresses from fiber to fiber.

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4. Influences the durability of the composites and must be resistant to a variety of chemical
environments.

Note:-
•Main objectives are to combine the fibers and resins such that thefibers are aligned in
the desired direction and held in place.
•Carbon grids are made using a non-woven process which alignscarbon fibers in a desired
configuration which may be 0/90 , [0/90]sor so, while simultaneously impregnating them with
polymer resin

ON X-axis:-Tensile Stress ( Ksi )

On Y-axis:-Tensile Strain (in. /in.)
Figure 5.2 Comparison of Tensile strength of fibers

The graph compares the tensile properties of the most common fiber types, carbon , aramid , and
fiberglass. Carbon is stiffest and strongest of the three.

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 CHAPTER-6
ADVANTAGES AND DISADVANTAGES

6.1 Advantages
Vacuum infusion provides a number of improvements over traditionally vacuum bagged parts
.These benefits include:
. Better fiber-to-resin ratio
. Less wasted resin
. Very consistent resin usage
. Unlimited set-up time cleaner
VARTM offers a better fiber-to-resin ratio than vacuum bagging .A typical hand lay-up usually
results in excess of 100%fabric weight by resin .Resin alone is very brittle ,so any excess
will actually weaken the part. Vacuum bagging can reduce this number significantly;
however, it is still not ideal and can lead to additional problems.

While vacuum bagging certainly improves on the hand lay-up, there is still a hand lay-up
involved .Because of this, the laminate will always begin in an over saturated state .Vacuum
pressure will remove much of the excess resin, but the amount removed still depends on a
variety of variables including reinforcement, resin, time factors ,and others.
Vacuum infusion takes a different approach, in that a vacuum is drawn while the materials are
still dry .From that point, resin is infused using vacuum pressure. Rather than starting with
excess and drawing resin out, VARTM starts with none and pushes resin in .Ideally, any
excess resin that is introduced will eventually be sucked out into the vacuum line .As a result
, only the minimum amount of resin is introduced .This lowers weight ,increases strength
,and maximizes the properties of fiber and resin .Parts constructed using VARTM can
approach desired levels of resin content.

Due to the nature of VARTM , resin usage becomes very predictable .While a standard lay-up
varies in resin content due to the human variable, VIP is remarkably consistent .Even when
creating

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Vacuum infusion provides another valuable benefit time .A frequent problem that can arise in
vacuum bagging is the time factor .Many resins have a pot-life of about 30 minutes, though
there are certainly some(such as our System 2000 Epoxy) that offer work times of up to2
hours .Even so, that time limit is extremely critical in vacuum bagging applications .Large
projects can easily approach the 2 hour mark, and even small, seemingly simple projects can
quickly turn frantic when a pesky leak in the vacuum seal cannot be found .Also, depending
on when the bag is applied, the amount of resin removed can vary from part to part.

Vacuum infusion, however ,offers unlimited set-up time .Because the vacuum is applied while
reinforcements are still dry ,there is no resin clock to work against .After the bag is applied,
leaks can be patiently sought out .If something is not sitting properly, simply release vacuum
and read just .No time constraints are introduced until it is decided that it is time to infuse
the resin. Until that moment, changes can be made again and again. Finally, vacuum infusion
is a much cleaner process .There are no brushes or rollers, and therefore no splashing or
spattering .No one will be required to hover over an open mold , saturating a laminate by
hand, trying not to drip on himself .In addition, there are less resin fumes to contend with
.Because the only fumes radiate from the resin reservoir, they are somewhat containable.
VARTM provides a cleaner, safer ,and friendlier work environment, though it is still
important to work in a well ventilated area and wear a respirator and other appropriate safety
equipment.

6.2 Disadvantages
Like any laminating process, VARTM is not without its drawbacks When attempting infusion
for the first time , it is important to keep the following ideas in mind.
 Complicated set-up
 Easy to ruin apart
 Trial and error
Though set-up is time-limit free, it is somewhat more complicated .Vacuum bagging requires the
placement of only the vacuum tubing .Vacuum infusion requires not only vacuum tubes but resin
inlets as well, not to mention in-bag extensions of these tubes .Placement of these vacuum and
resin lines varies from part to part, and there is no one way to set them up. These considerations
must be evaluated prior to lay-up, or else the part could be ruined.

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This leads into the next pitfall ;it is very easy to destroy a part .Typically, once infusion begin
,there is little that can be done to correct any errors .For example ,if a leak were to occur, even
the smallest amount of air introduced could be potentially fatal to a part .It would probably result
in resin pooling under saturation, or even a complete stoppage of resin flow .Though there some
cases where problems can be corrected ,it should not be expected .The best protection from
disasters careful planning.

Due to the complexity and ease of error , VARTM should be viewed as a trial and error process.
The best mind set to have when attempting vacuum infusion for the first time is that a few
parts(or more than a few)will be ruined before getting it right .The trick is to carefully document
each attempt in order to learn from each trial .Keep track of the resin flow rates .Determine
where the resin is reluctant to go and find away to get it there .Even the smallest modification
can yield drastically different results .Practice with small quantities and inexpensive materials
before undertaking full-scale projects .

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 CHAPTER-7
VARTM PRODUCTS

7.1 Industries using VARTM process.

1. Air to air missile casings.
2. Stealth navel attack vessels.
3. Wind powered energy.
4. Vehicle replacement parts.
5. Aircraft fairings6.Manufacturing of turbine blades.

Figure 8.1 Industries using VARTM

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7.2 Products made by using VARTM process.
1. Eagle Rudder.
2. Generic Wing Spar.
3. Wind Turbine Blade.
4. JASSM’
5. Contest 55 Hull and Upper Deck.
6. Submersible Pressure Hull Ends.
7. Ariane-5 LOX Fairing

Figure 8.2 Product made by using VARTM

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 CONCLUSION
VARTM is the subject of many research topics .The process has great potential for general use
,and for parts that are not highly loaded .This process seems like it will make its way into the
aircraft industry in a reverse order from the general market .This is likely make its way
because of the funding being funneled its way from other industries that want these
materials in their product ,but cannot afford the autoclaves, the refrigerators, and the
working tools needed for pre-pre quality parts. This process will be seen in industry in years
to come, and is currently being integrated at a rapid rate.

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 REFERENCE

[1] S.N. C. Correia, F. Robitaille, A. C. Long, C. D. Rudd, P. Šimáček and S. G. Advani , “Use
of Resin Transfer Molding Simulation to Predict Flow, Saturation, and Compaction in the
VARTM Process”, J. Fluids Eng 126(2), pp: 210-215 , May 03, 2004.
[2] VARTM PROCESS WITH SOME MODIFICATIONS by Anupam Dhyani [Book]
[3] Training report, In B.H.E.L BHOPAL ,Topic-Manufacturing of turbine.
[4] http://www.compositesworld.com/columns/resin-infusion-processes
[Accessed on 19/11/2016]
[5] https://www.hindawi.com/journals/jnm/2006/032803/abs/
[Accessed on 15/11/2016]
[6]http://www.composites.ugent.be/home_made_composites/organizing_your_composite_works
hop.html
[Accessed on 17/11/2016]

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