Resin Transfer Molding

(RTM)

Assoc. Prof. Dr. Seksak Asavavisithchai

Department of Metallurgical Engineering
Faculty of Engineering
Chulalongkorn University
E-mail: [email protected]
 Resin Transfer Molding (RTM)
 Resin Transfer Molding (RTM) is a low pressure, closed molding process
which offers high-quality dimensional and surface finish composite
moldings using liquid thermoset polymers reinforced with various forms of
fiber reinforcements.
 Typically polymers of Epoxy, Vinyl Ester, Methyl Methacrylate, Polyester
or Phenolic are used with typically fiberglass reinforcement.
 Other reinforcements, are offered for more demanding applications such as
Aramid, Carbon and Synthetic fibers either individually or in combination
with each other.
 The matrix selection of polymer and reinforcement, dictates both molding
material cost, as well as molding mechanical and surface finish
performance.
 Along with the polymer and reinforcement the addition of mineral fillers
may be added to enhance fire retardantcy, flex modulus and surface finish.
Resin Transfer Molding (RTM)
 Resin Transfer Molding (RTM)
 Reinforcements are presented in their dry form to the mold in either
binder-bound chopped mat, random-continuous strand mat or woven cloth
format.
 The fiber has been either "preformed" to the exact shape of the molding
tool in a previous operation or is hand-tailored during the loading process
in the molding tool.
 After the fiber is installed into the mold, a premixed catalyst and resin is
injected into the closed mold cavity encapsulating the fiber within.
 After the resin has cured, the mold can be opened and the finished
component removed.
 Resin Transfer Molding (RTM)
 The primary surface of the molding may be gel-coated, a process of
spraying the mold surface before installing the fiber.
 If a gel coat is not required, the exterior finish would be the same from the
front to back of the molded part.
 RTM having the inherent advantage of low-pressure injection usually does
not exceed 100 psi of resin injection pressure during the mold-fill process.
 The most common application of RTM composites is molded with a cross-
section thickness of 4 mm with 30% fiber content by weight of the total
laminate.
Resin Transfer Molding (RTM)
Resin Transfer Molding (RTM)
Resin Transfer Molding (RTM)
Resin Transfer Molding (RTM)
 Reinforcements Used in RTM
 Type
 E-glass, S-glass
 Carbon/graphite
 Aramid
 Form
 Mat
 Fabric
 Textile preform architecture
(knitted, braided, 3-D stitched)
 Preforms - preshaping of reinforcement
 Resins Used in RTM
 Polyester, vinyl ester, epoxy
 Desired resin characteristics
 Must remain liquid as it is held in the reservoir prior to injection
 Must impregnate fiber preform quickly and uniformly without voids
 Must gel as quickly as possible once impregnation occurs (fast cycle
time)
 Must possess sufficient hardness to be demolded without distortion
 Low viscosity critical (< 1,000 cps to impregnate preform loading of 50%)
 Low viscosity resin
 Injection temp (typically elevated) of resin should be held as close as
possible to minimum viscosity to insure preform impregnation, yet higher
temp accelerates cure, cutting into injection time
 Design of Preforms
 Compression of fiber preform into the mold (denser the fiber, the more
resistance it offers to impregnation by resin)
 Fiber orientation (resin flows faster along the length of the fiber than
across it)
 Multiple layers or plies (impede or complicate the resin distribution)
 RTM Equipment
 Resin/curing agent (catalyst) mixing equipment
 Positive displacement piston pumping cycle
 Maintain accurate ratio control between resin and curing agent
 RTM process requires low injection pressures (30 psi - 100 psi)
 Piston type positive displacement pumps are critical due to changing
back pressure conditions - as resin is pushed through reinforcement an
increasing back pressure builds against metering pumps - if slippage
occurs at pump, resin/curing agent ratio will be affected
 With resin system components accurately metered, sent through flexible
hoses to a mix head
 Advantages of RTM Process
 Moldings can be manufactured to close dimensional tolerances.
 Components will have good surface finish on both sides.
 Selective reinforcement and accurate fiber management is achievable.
 Ability to build-in fiber volume fraction loadings up to 65%.
 Uniformity of thickness and fiber loading, resulting in uniform shrinkage.
 Inserts may be incorporated into moldings.
 Tooling costs comparatively low compared to other manufacturing processes.
 Uses only low pressure injection.
 Low volatile emission during processing.
 Ability to produce near net shape moldings, reducing material wastage.
 Process can be automated, resulting in higher production rates with less scrap.
 Ability to mold complex structural and hollow shapes.
 Low resultant voidage in molded components.
 Ability to achieve from 0.1mm to 90mm laminate thickness.
 Disadvantages of RTM Process
 Preform process
 Preparation can be labor intensive
 Process waste may be high
 Because preform lacks strength may have to be assembled in mold
(tying up mold)
 Preforms may be oversized in order to pultrude from tool edge to provide
escape route for displaced air and excess resin
 Oversized preforms will have to be trimmed (sealing or close-out will be
required over exposed reinforcement to prevent potential path for moisture
ingress)
 Movement of reinforcement during injection (fiber wash)
 Control of resin uniformity difficult - radii and edges tend to be resin rich
 Higher speed versions of process undeveloped - still problems filling large
parts with high reinforcement content at low pressure
 As part consolidation increases
 High losses for manufacturer if part scrapped
 Replacement cost to consumer can be significant
RTM Applications
Resin Transfer Molding (RTM) Evaluation
Thank You for Your Attention