Advanced Materials
Intelligent Processing Center (AMIPC)

Office of Naval Research
Center of Excellence
for RTM and VARTM Processing

AMIPC Technology Transfer Highlights

Established in 1997, the Advanced Materials Intelligent Processing Center (AMIPC) is aimed at developing and demonstrating intelligent RTM and VARTM processing of polymer composites based on automations, sensors, and controls to improve quality and reduce variability and cost. The objective is the creation of different hardware and software tools, such as mold-filling simulations, sensor technologies, active controllers, versatile resin injection systems, and mold design methodologies for liquid composite molding (LCM) processes.The program development, and proveout using our workcells. These technologies have been successfully transferred to industry to reduce costs and to improve quality.

The program is currently in Phase V. Phases I and II of the program were focused on RTM, while Phase III focused on VARTM technology. In 1999, funds from the Office of Naval Research via Defense University Research Instrumentation Program (DURIP) established the National VARTM Testbed for low-cost, high-quality processing of composite structures. Phase IV addressed the use and the development of software and hardware tools to further extend the processing science of RTM and VARTM and to transfer the technology to NAVAIR and NAVSEA composites manufacturing industries in order to improve quality and affordability.

Phase V is concerned with expanding the suite of software and hardware tools developed in the previous phases to address the needs of the Navy for revolutionary multifunctional composite materials. Multi-functionality requirements arise from various needs, such as fire protection, blast resistance, and embedded antennas as well as signature management using advanced photonics and left-handed materials. Meeting these requirements involves processing of multiple resins encapsulating different inserts with possible interconnections for power supply, creating the next generation of composite structures. Current tasks address the intelligent processing aspect for multifunctional design, followed by assessment projects to explore multifunctional attributes of composites.

The co-principal investigators are Suresh G. Advani and John W. Gillespie, Jr. The ONR Program Manager is Ignacio Perez.

Thus far, the AMIPC program has developed the following tools:

• Liquid Injection Molding Simulation (LIMS), developed at UD-CCM, is a comprehensive, 3-D simulation software tool for mold filing, which explores a variety of filling scenarios. LIMS enables investigating processing conditions in RTM and VARTM.
  
• VARTM Injection System Design Tool (VARTM-ISD) is an analytical tool for the design of sequential line injection locations for a long, flat part; and for the prediction of flow front length and infusion time. Its database allows for the selection of distribution media, fabric, and resin.
  
• Simulation-Based Liquid Injection Control (SLIC) uses LIMS as a slave and can automatically generate the location of the sensors and control actions needed to counteract irreproducible flow disturbances that occur during mold filling .Eventually, SLIC will provide an integrated solution to create an intelligent RTM system seamlessly linking design to automation.
  
• RTM Automation System (Auto-RTM) is a LABView application designed to implement control strategies developed by SLIC.
  
• Permeability Measurement Workstation (PERMSTAT) automates the measurement of 3-D permeability tensors of a preform in VARTM applications.
  
• Smart Sensors, including point, line, and grid sensors, were used to detect resin flow inside a closed mold. TekScan, a commercial grid pressure sensor, was modified to detect resin flow.
  
• The VARTM Testbed was used to measure the dimensional changes during mold filling with the help of a laser and the location of the flowfront with the help of smart sensors.

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