1. IFB
• Application and validation of all project CAE tools to be used for preforming and infusion was completed and training provided to Airbus.
• Permeability characterisation of fabrics (undeformed, sheared and compacted) for the Airbus fabrics was completed and data transfered to Airbus.
• Porosity investigations covered experimental and numerical studies to predict porosity distribution.
• A testing programe for the flat plates was completed and conducted for porosity studies. This work will be continued at IFB and published.
• Porosity characterization for Airbus fabrics and RTM6 was completed and published in 2 MSc theses.
• Permeability characterization was extended in order to account for aging and activation of binder with data transferred to Airbus.
• Design and manufacture of tooling for the first and second RTM pilot plants were completed. These will be used in future IFB research projects.
• The demonstrator moulds where manufactured and sensors integrated.
• Filling simulation, including porosity model and previously developed reinforcement deformation models, were performed according to a testing plan agreed with Airbus.
• Simulation results were compared to online monitoring results. In particular sensors flow estimation was compared with simulation results for all the cases studied.
• A training course was delivered at Airbus on permeability testing, porosity modelling and infusion analysis.
2. TWI Ltd
• Development and manufacture of tooling for flow monitoring. This will be published in a PhD thesis.
• Development of flow monitoring sensor and measurement system completed.
• DSC, DMA and TMA at different degree of cure has been completed and results published in deliverables.
• Experiments on different sensor configurations were conducted. Sensor manufacturing process and testing/calibration method were finalised.
• The effect of reinforcement with different fibre types were accessed including effect of reinforcement conductivity and penetration depth.
• Sensor distortion (flat and curved/bent sensors) was assessed using a series of flat and L-shape composite infusion trials.
• In order to establish the ability to detect race-tracking, sensor at different orientations were investigated.
• The sensor system was installed in the pilot line at IFB and three sets of pilot plant trials were successfully performed.
• A training course was delivered at Airbus on the sensor development, manufacturing, calibration, installation, measurements and data interpretation.
3. Cranfield University
• Material properties characterisation and constitutive models development was completed covering cure kinetics, specific heat capacity, thermal conductivity, viscosity and resin shrinkage. These results were published.
• Thermal boundary conditions variability (heat transfer coefficient, tool temperature and stochastic object for thermal BC variability.
• Process modelling with a deterministic cure model implemented in MSC.MARC.
• Variability propagation and simulation.
• Surrogate cure model (using kriging and stochastic inversion using MCMC), and published in a PhD thesis
• Uncertainty quantification of material properties was completed covering viscosity variations and boundary conditions (tool temperature, heat transfer coefficient).
• Stochastic objects development representing properties (cure kinetics, viscosity) and process (tool temperature, heat transfer coefficient) was finished and published.
• Process modelling of flow and cure process using FE software (PAM-RTM, MSC.MARC).
• Stochastic simulation of flow and cure process using Monte Carlo scheme was validated.
• Surrogate model development based on Kriging method replacing Finite Element model reducing computational effort.
• Validation of inversion procedure for the pilot line during filling and curing stages.
• A training course was delivered at Airbus on resin characterisation, cure kinetics and the surrogate analysis methods.
