Investigation of unsaturated flow in woven, braided and stitched fiber mats during mold-filling in resin transfer molding

In Resin Transfer Molding (RTM), which is a process to manufacture polymer composites, the impregnation of fibrous reinforcement in the form of mats by a thermosetting resin is modeled as the flow of a Newtonian liquid through a single length-scale porous medium. While this approach is sufficiently accurate for ran-dom fiber-mats, it can lead to appreciable errors when applied to woven, braided, or stitched fiber-mats that contain two length scales. This work investigates the primary factors governing the isothermal unsaturated flow through such dual-scale porous media. Two studies were conducted to better understand this phenomenon: the first experimentally investigated the flow, while the second theoretically modeled the flow and identified important parameters affecting such a flow with the help of dimensionless analysis. In the first study, one-dimensional constant injection rate experiments were performed using various fiber mats. The unsaturated flow behavior of various mats was characterized using a constant sink term in the continuity equation. Results indicated that for a given fiber-mat, the magnitude of the sink effect was a function of the capillary number. In the second study, a numerical model was developed to describe flow through dual-scale preforms in which the two flow domains, the inter- and intra-tow regions, were coupled. We identified a dimensionless number called the sink effect index psi that characterizes the magnitude of liquid absorption by the tows and is a function of the relative resistance to flow in the tow and inter-tow regions, and the packing density of the tows. The parametric study of this index with the help of numerical simulations reveals its influence on the flow and identifies the distinct transient and steady-state flow regimes.