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Processing of Polymers and Composites: Lecture 23 - 09/03/2020

This document discusses the Resin Transfer Molding (RTM) process for processing polymers and composites. RTM involves injecting a thermosetting resin under pressure into a heated mold containing a fiber preform. The resin flows through the preform, curing as it saturates the fibers. After curing is complete, a solid composite part is formed. RTM is used to make various automotive and aircraft parts. The document outlines the basic RTM process steps and provides information on advantages, limitations, and variations like VARTM.

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MK Saravanan
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40 views9 pages

Processing of Polymers and Composites: Lecture 23 - 09/03/2020

This document discusses the Resin Transfer Molding (RTM) process for processing polymers and composites. RTM involves injecting a thermosetting resin under pressure into a heated mold containing a fiber preform. The resin flows through the preform, curing as it saturates the fibers. After curing is complete, a solid composite part is formed. RTM is used to make various automotive and aircraft parts. The document outlines the basic RTM process steps and provides information on advantages, limitations, and variations like VARTM.

Uploaded by

MK Saravanan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Processing of Polymers and Composites

Lecture 23 – 09/03/2020

Dr S. Gowthaman
Indian Institute of Information Technology Design and Manufacturing Kancheepuram
Chennai - 600127
Resin Transfer Molding (RTM) Process

• The process involves injecting a precatalyzed thermosetting resin under pressure into a heated mold
cavity that contains a porous fiber preform.
• During mold filling, the resin flows into the mold and experiences exothermic curing reactions, causing
its viscosity to increase over time and finally solidification.
• After the fiber preform is completely saturated with resin, cure reactions continue past the gel-point to
form a cross-linked polymer.
Resin Transfer Molding (RTM) Process
Applications
• RTM is used in automotive, aerospace, sporting goods, and consumer product applications.
• The structures typically made are helmets, doors, hockey sticks, bicycle frames, windmill blades, sports car
bodies, automotive panels, and aircraft parts.
• Some aircraft structures made by the RTM process include spars, bulkheads, control surface ribs and
stiffeners, fairings etc
Resin Transfer Molding (RTM) Process
1. A thermoset resin and catalyst are placed in tanks A and B of the
dispensing equipment.
2. A release agent is applied to the mold for easy removal of the
part. Sometimes, a gel coat is applied for good surface finish.
3. The preform is placed inside the mold and the mold is clamped.
4. The mold is heated to a specified temperature.
5. Mixed resin is injected through inlet ports at selected
temperature and pressure. Sometimes, a vacuum is created
inside the mold to assist in resin flow as well as to remove air
RTM dispensing equipment bubbles.
6. Resin is injected until the mold is completely filled. The vacuum
is turned off and the outlet port is closed. The pressure inside
Control parameters: Injection
the mold is increased to ensure that the remaining porosity is
pressure, vacuum in the mold, resin
collapsed.
temperature, viscosity, and preform
permeabilities. 7. After curing for a certain time, the composite part is removed
from the mold.
Resin Transfer Molding (RTM) Process

Raw Materials Fabrics / Preforms / Mats of - Glass, Kevlar, and carbon fibers along with
epoxy, polyester, and vinylester resins.

• Low pressure process – less expensive; Steel / aluminium / wood / composite


Tooling
molds are used.

Methods of Applying Heat and Pressure


• The RTM equipment has a compressor that injects resin at a certain pressure. This
injection pressure helps the resin to flow inside the mold through porous media and
allows the resin to fill the cavity.
• Temperature is maintained by heating the mould, the emperature selection during RTM
processing depends on the type of resin.
Resin Transfer Molding (RTM) Process - Advantages
1. Initial investment cost is low because of reduced tooling costs and operating expenses as
compared to compression molding and injection molding.
2. RTM processing can make complex parts
3. RTM provides for the manufacture of parts that have a good surface finish on both sides.
Sides can have similar or dissimilar surface finishes.
4. RTM allows for production of structural parts with selective reinforcement and accurate
fiber management.
5. Higher fiber volume fractions, up to 65%, can be achieved.
6. A wide variety of reinforcement materials can be used.
7. RTM offers low volatile emission during processing because of the closed molding
process.
8. RTM offers production of near-net-shape parts, hence low material wastage and
reduced machining cost.
9. The process can be automated, resulting in higher production rates with less scrap.
Resin Transfer Molding (RTM) Process - Limitations
Tooling and equipment costs for the RTM process are higher than for hand lay-up and
spray-up processes.
Variations of the RTM Process
VARTM – Vacuum Assisted Resin Transfer Moulding
• Cost-effective - tooling costs are cut in half because
one-sided tools such as open molds are used to make
the part.
• In this infusion process, fibers are placed in a one-sided
mold and a cover, either rigid or flexible, is placed over
the top to form a vacuum-tight seal.
• A vacuum procedure is used to draw the resin into the
structure through various types of ports.
• Closed mould process – emissions are low
• High fiber volume fraction (70%) is achieved

Set up similar to vacuum


bagging; Breather / bleeder can
be used; Resin flow medium is
used; Inlet / outlet tube used
Videos
For RTM - https://www.youtube.com/watch?v=kHuC51OyfWM

For VARTM Process - Video Demonstration

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