Resin Infusion

Resin Infusion
Definition
Not easy! (the definition, or the technology!) Using vacuum to pull resin into the voids created in a composite component
Monolithic Core Inserts Structure Patent Protection

Resin Infusion
Common Types
Using a mesh or flow promotion material placed on the laminate

Using core material to assist flow

Infusion using a flow promoting fabric, which remains integral to the laminate

Resin Infusion
Infusion using a flow promotion mesh
The most common system in use Provides a consistent, predicable flow front Leaks and problems are easily seen Compatible with more fabrics ( though some offer better permeability than others) Problems (leaks) can be repaired (even using additional resin/vacuum sources if really necessary) Mesh and resin included are both removed and are scrap Labour intensive to apply consumables Difficulty in ensuring flow is reaching opposite side of laminate stack Often also requires core cuts to provide flow to both skins in sandwich infusion

Resin Infusion
The Principle
Infusion medium Vacuum Outlet

Dry Fabric Stack (including core if required) Resin Inlet

Resin Infusion
The Principle
Infusion medium Vacuum Outlet

Dry Fabric Stack (including core if required) Resin Inlet

Resin Infusion
The Principle
Infusion medium Vacuum Outlet

Dry Fabric Stack (including core if required) Resin Inlet

Resin Infusion
The Principle
Infusion medium Vacuum Outlet

Dry Fabric Stack (including core if required) Resin Inlet

Resin Infusion
The Principle
Infusion medium Vacuum Outlet

Dry Fabric Stack (including core if required) Resin Inlet

Resin Infusion
Infusion using a core
Uses a cut pattern in the core materials to provide resin flow Becoming more common, mainly in applications where weight is non-critical Flow front is invisible - difficult to see problems Problems are very difficult to repair during the infusion Changes in core cut, incorrect placement or misalignment can greatly affect the flow All additional resin used in flow promotion remains in the component Additional weight Effect on mechanical properties Effect on print on coated structures Does not use additional consumables

Resin Infusion
Infusion using a flow reinforcement fabric
Generally specifically designed very open weave fabrics (sometimes 3 dimensional) which allow resin to move through the component Easier to apply than a core, and integral unlike mesh Adds considerable weight to the component Alters mechanical properties - creating a very resin rich band through the laminate Change permeability on corners, bridges etc Does not comply with core materials very well often requires the addition of the core cut infusion policy also

Resin Infusion
Its Benefits:
Allows fast lamination of multiple plies and often core materials in one process (no debulking) Often uses less consumables than a wet-laminate vacuum consolidated component Is a very clean process (or should be) Allows the use of standard curing resins as opposed to hot-melt technology (prepreg, SPRINT) Does not require a complex oven to cure (though often requires some heat) Uses generally standard fabrics though careful selection required

Resin Infusion
Its Benefits:
Gives a very good Vf typically 0.58-0.68 with E-glass Gives lower void contents (1% average achievable) Repeatable process times, weights and quality Laminates can be redesigned to accommodate higher obtainable properties Epoxy infusion reduces exotherm and high cure temperatures from ester resins Low shrinkage capability from epoxy gives less fabric print, less core print, reduced finishing No styrene (Poly/Vinyl infusion resins are 55%+ styrene

Resin Infusion
But
Is can be seen as a high risk technology complete success or complete failure High cost of waste resin in consumables Requires careful setup, and trained operators to design an infusion strategy that will work Infusion laminates will be thinner than those designed in wet laminated engineering typically 10-15% thickness reduction Generally a heated cure will be needed (though this does not need to be high temperature and can be as simple as a heat blower and polythene tent) Positioning and consolidating plies and core can be difficult, especially with high numbers of plies

Benefits of epoxy in Infusion

MECHANICAL
ILSS Shrinkage Epoxy shrinkage (2%) is far lower than Vinyl or Vinyl ester (8%) Emissions Strain Capability Epoxy (8-9%) Vinyl (3-4%) Fiber Volume Fraction Emphasis on ILSS Long Gel Times

Benefits of Epoxy in Infusion

PROCESSING
Epoxy viscosity is consistent Infusion processing highlights the control of exotherm Epoxy allows optimisation of cure cycles infusion at elevated temperature can allow faster curing and postcuring whilst retaining workable resin properties Removal of CFM/CSM from designs removes resin-rich areas which cause higher shrinkage and have structurally poor properties

Using Infusion
Planning and Designing
Software and modelling Independent consultants

Offer planning services for design of infusion, layout of consumables Can sometimes model where resin will flow and when

The requirement for these can often be superseded by some basic training in infusion systems

Using Infusion
Gurit Infusion Technology
We can assist on infusion setup, layout and specification of materials
Based on experience from many infusion project on components from 1lb to 5500lb in every market Internal testing on flow, fabric selection, resin use

We cannot provide a guarantee for infusions, but the composite processing team are there to provide support at every step A range of consumables valves, etc and suppliers
These are not the cheapest but they are tried and tested and flow is well understood using them

Summary
So
Infusion can provide very high quality components with excellent mechanical properties Once implemented, the process is very repeatable Improves health and safety, working environment and quality control Requires some development and some commitment to a stepup in technology Ideally implemented on new projects where the component can be optimised for the process (and tooling) , though retrofitting is possible Makes a significant step up the technology ladder but benefits of Prepreg/SPRINT can start to make them only a small step above infusion.