This investigation focuses on nanoparticle filtration in the processing of multiscale carbon and glass fibre composites via resin transfer moulding. Surface modified and unmodified carbon nanotubes (CNTs) were incorporated into a commercial epoxy resin. The dispersion quality was evaluated using electrical measurements of the liquid suspensions. The manufacturing process was adapted to the challenges posed by the modified rheological behaviour of the CNT loaded resin. Nanoparticle filtration was observed; with some of the unmodified systems following so called 'cake filtration' behaviour. This resulted in non linear flow behaviour that deviated from the ideal response observed in RTM filling in conventional composites. The electrical conductivity of relatively high fibre volume fraction multiscale carbon and glass laminates increased by less than an order of magnitude with the addition of the nanotubes.
This paper presents analytical and numerical models of liquid moulding of hybrid composites. An 1-D analytical solution of Darcy's problem, accompanied by nanoparticle filtration kinetics and conservation, has been developed. A non-linear finite difference model incorporating variations in permeability, porosity and viscosity as a function of local nanoparticle loading was formulated. Comparison of the two models allowed verification of their validity, whilst a mesh sensitivity study demonstrated the convergence of the numerical scheme. The limits of validity of the analytical solution were established over a range of infiltration lengths and filtration rates for different nanoparticle loadings. The analytical model provides an accurate and efficient approximation of through thickness infusion of hybrid composites, whereas use of the numerical scheme is necessary for accurate simulation of in-plane filling processes. The models developed here can serve as the basis of process design/optimisation for the production of hybrid composites with controlled distribution of nano-reinforcement.
The infusion, flow and cure of RTM6 resin in a carbon fibre reinforced composite preform have been monitored using a variety of multiplexed fibre optic sensors. Optical fibre Fresnel sensors and tilted fibre Bragg grating (TFBG) sensors were configured to monitor resin infusion/flow in-plane of the component. The results obtained from the different sensors were in good agreement with visual observations. The degree of cure was monitored by Fresnel sensors via a measurement of the refractive index of the resin which was converted to degree of cure using a calibration determined from Differential Scanning Calorimetry. Fibre Bragg grating sensors fabricated in highly linearly birefringent fibre were used to monitor the development of transverse strain during the cure process, revealing through-thickness material shrinkage of about 712 and residual strain of 223 . An alternative approach to infusion monitoring, based on an array of multiplexed tapered optical fibre sensors interrogated using optical frequency domain reflectometry, was also investigated in a separate carbon fibre preform that was infused with RTM6 resin.
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