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Correction: Troschitz et al. Joining Processes for Fibre-Reinforced Thermoplastics: Phenomena and Characterisation. <i>Materials</i> 2022, <i>15</i>, 5454.

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Flow Front Monitoring in High-Pressure Resin Transfer Molding Using Phased Array Ultrasonic Testing to Optimize Mold

Linus Littner1, Richard Protz2, Eckart Kunze2

  • 1Institut für Kunststofftechnik (IKT), University of Stuttgart, 70569 Stuttgart, Germany.

Materials (Basel, Switzerland)
|January 11, 2024
PubMed
Summary
This summary is machine-generated.

Flow front monitoring in high-pressure resin transfer molding (HP-RTM) using phased array ultrasonic testing improves process control. This non-destructive method enhances simulation accuracy by approximately 70% for defect reduction.

Keywords:
HP-RTMflow front monitoringflow simulationinline measurementprocess optimizationthick-walled compositeultrasonic testing

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Processes
  • Non-Destructive Testing

Background:

  • Fiber-reinforced plastics production via resin transfer molding (RTM) can suffer from defects like fiber misalignment, especially in high-pressure RTM (HP-RTM).
  • These defects significantly reduce mechanical properties, necessitating precise control over the manufacturing process.
  • Current simulative approaches offer basic mold filling designs but struggle to replicate real-world behavior due to numerous variables.

Purpose of the Study:

  • To investigate the application of phased array ultrasonic testing for flow front monitoring in HP-RTM molds.
  • To reduce the integration effort of monitoring tools into the manufacturing process.
  • To enhance the accuracy of process simulations by comparing experimental data with simulation results.

Main Methods:

  • Utilized phased array ultrasonic testing to monitor the flow front during the production of glass fiber-reinforced polyurethane resin test specimens.
  • Recorded individual line scans with a phased array ultrasonic probe, analyzing data with a spatial resolution of 0.85 mm and averaging over a 6.8 mm window.
  • Determined local flow velocities by varying the probe orientation and line scan direction.
  • Conducted process simulation studies incorporating locally varying fiber volume contents.

Main Results:

  • Successfully monitored the flow front in an HP-RTM mold using phased array ultrasonics.
  • Established a method to determine local matrix system flow velocities during mold filling.
  • Achieved an approximate 70% improvement in agreement between experimental measurements and process simulations.

Conclusions:

  • Phased array ultrasonic testing is a viable non-destructive method for flow front monitoring in HP-RTM.
  • This technique allows for drawing conclusions about global flow behavior even with a locally limited measurement range.
  • Improved correlation between simulation and experiment aids in minimizing defects and optimizing the HP-RTM process.