Communication to the Editor

GAS FLOW TEST OF BRAIDED PREFORM QUALITY FOR RESIN

TRANSFER MOLDING

Sun K. Kim and Isaac M. Daniel*

Robert R. McCormick School of Engineering and Applied Science

Northwestern University, Evanston, IL 60208, US

*Author To whom correspondence should be addressed.

(Received 3/03; accepted 9/03 )

The quality of a resin transfer molded part
depends greatly on the state of the preform
structure. Using regular preforms for complex
composite parts can cause severe difficulties
during placement, such as draping, shearing and
folding. To avoid these difficulties, braided or
stamped preforms are often employed for resin
transfer molding. In this case, it is essential to
limit the permeability variation of the preform
within an admissible range.
The quality of a resin transfer molded part
depends greatly on the state of the preform
structure. Using regular preforms for complex
composite parts can cause severe difficulties
during placement, such as draping, shearing and
folding. To avoid these difficulties, braided or
stamped preforms are often employed for resin
transfer molding. In this case, it is essential to
limit the permeability variation of the preform
within an admissible range.

The gas flow method is beneficial in that it can
test flow conductance of the preform without any
impairment [1]. In this work, we provide a
method for preform quality test prior to
placement into the mold. The rigidity of braided
preforms allows easy measurements of flow
conductance through the thickness direction. It
is assumed here that out-of-plane and in-plane
permeabilities are interrelated. Pressure drop in
the thickness direction is measured over the
length of the preform at a constant flow rate. A
large deviation in local permeability is considered
a defect that can cause a dry spot in the final part.
The gas flow method is beneficial in that it can
test flow conductance of the preform without any
impairment [1]. In this work, we provide a
method for preform quality test prior to
placement into the mold. The rigidity of braided
preforms allows easy measurements of flow
conductance through the thickness direction. It
is assumed here that out-of-plane and in-plane
permeabilities are interrelated. Pressure drop in
the thickness direction is measured over the
length of the preform at a constant flow rate. A
large deviation in local permeability is considered
a defect that can cause a dry spot in the final part.

Fig. 1: Overview of the experimental setup

Advanced Composites Letters, Vol.12, No.4, 2003 161

 Sun K. Kim and Isaac M. Daniel
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Sample results are shown in Figs. 3(a) and 3(b).
The pressure drop varies noticeable for both
cases. This reveals that permeability changes
drastically from location to location. The pressure
drop variation at both ends is more pronounced.
There are several spots with significantly high
pressure-drops. This local deficiency in flow
conductance may or may not affect the entire
flow. However, it may produce many minor dry
spots and micro voids [2]. Such variation was
more significant in preform B than in preform A
as can be seen in the figures. The pressure
fluctuation in preform A is normal and
admissible, while that in preform B is
exceptionally high. A practical criterion for
admissibility can be developed by accumulating
data sets. Such a criterion can be determined
statistically, but it can vary from application to



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application. It may also depend on the required
quality of the final product.
In summary, we have proposed a gas flow
method, which can test the quality of braided or
stamped preforms prior to placement into the
mold. The method was applied to a braided
preform for a curved I-beam. A sample
experimental setup and results were shown and
the applicability of the method was verified.
The work described in this paper was conducted
in the Centre for Intelligent Processing of
Composites of Northwestern University
sponsored by the Office of Naval Research
(ONR). The authors are grateful to Dr. Ignacio
Perez of ONR for his encouragement and
cooperation.


 

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Fig. 3: Test result on inside flange of preform. Pressure readings along with angular position: (a) preform A; (b)
preform B.

162 Advanced Composites Letters, Vol.12, No.4, 2003

 Gas Flow Test of Braided Preform Quality for Resin Transfer Molding

1. Kim, S. K., Opperer, J. G., and Daniel, I.

M., “Detection of Local Preform Defects by
Gas Flow Method and Statistical Analysis”,
Advanced Composites Letters, submitted.

2. Patel, N., and Lee, L., J., “Modelling of

void formation and removal in liquid
composite molding I, Wettability analysis”,
Polymer Composites, 17 (1996), 96-103.

Advanced Composites Letters, Vol.12, No.4, 2003 163