1. Composite Group Manufacturing Montana State University Pancasatya “Tiok” Agastra 27 November 2012

2. Impetus Superior mechanical performance of large composite structures through energy efficient manufacturing –Substructural details: ply drops, sandwich construction, ply joints Low cost manufacturing and increased turnover rate Understanding of resin reaction kinetics

3. Approach Quantification of manufacturing parameters –Industry-accepted composite manufacturing method: Resin Transfer Mold (RTM), Vacuum Bag Manufacturing modeling using FEA –Fluid flow, including free surface analysis –Heat transfer with autocatalytic reaction kinetics –FEA packages: ANSYS FLOTRAN, ANSYS CFX, COMSOL

4. Governing Equations for Manufacturing Modeling Navier-Stokes Equation with Darcy’s Law Conduction and Convection Enthalpy rate of release Autocatalytic Rate Law Integral Form of the Rate Law FLUID FLOW HEAT TRANSFER REACTION KINETICS

5. Manufacturing Methods RTMVacuum Bag

6. Manufacturing Parameter Quantification & Resin Characterization FlowrateTemperature Differential Scanning Calorimetry

7. Manufacturing Milestone

8. Blade Root Manufacturing

10. “Brick” Laminate

11. Microflow-Scale Modeling Resin flow in wind turbine blade materials is a complicated local and global phenomenon (channel flow plus D’Arcy flow in strands) Baseline Fiber Strand Permeability 6.16E-14 m² Higher Fiber Strand Permeability 6.16E-12 m² TRANSVERSE FLOWAXIAL FLOW Knytex D155 Cross Sectional Area

12. Heat Transfer Modeling RTMVacuum Bag

13. Fabric Compaction

14. COMSOL Coupled-Field Thermal-Fluid-Convection RTM with incoming resin

15. Large Scale Application

16. Future Work Flow properties –Viscosity and degree of cure correlation –Permeability and compaction Chemical and thermal properties –Thermal conductivity –Enthalpy release rates and heating rate