Sensor Fusion for Simultaneous Estimation of In-Plane Permeability and Porosity of Fiber Reinforcement in Resin Transfer Molding.

To meet the expectation of the industry, resin transfer molding (RTM) has become one of the most promising polymer processing methods to manufacture fiber-reinforced plastics (FRPs) with light weight, high strength, and multifunctional features. The permeability and porosity of fiber reinforcements are two of the primary properties that control the flow of resin in fibers and are critical to numerical simulations of RTM. In the past, various permeability measurement methods have been developed in the literature. However, limitations still exist. Furthermore, porosity is often measured independently of permeability. As a result, the two measurements do not necessarily relate to the same entity, which may increase the time and labor costs associated with experiments and affect result interpretation. In this work, a measurement system was developed by fusing the signals from capacitive sensing and flow visualization, based on which a novel algorithm was developed. Without complicated sensor design or expensive instrumentation, both in-plane permeability and porosity can be simultaneously estimated. The feasibility of the proposed method was illustrated by experiments and verified with numerical simulations.

Retrieving Equivalent Shear Viscosity for Molten Polymers from 3-D Nonisothermal Capillary Flow Simulation.

For highly viscous polymer melts, considerable fluid temperature rises produced by viscous heating can be a disturbing factor in viscosity measurements. By scrutinizing the experimental and simulated capillary pressure losses for polymeric liquids, we demonstrate the importance of applying a viscous heating correction to the shear viscosity, so as to correct for large errors introduced by the undesirable temperature rises. Specifically, on the basis of a theoretical derivation and 3-D nonisothermal flow simulation, an approach is developed for retrieving the equivalent shear viscosity in capillary rheometry, and we show that the shear viscosity can be evaluated by using the average fluid temperature at the wall, instead of the bulk temperature, as previously assumed. With the help of a viscous Cross model in analyzing the shear-dominated capillary flow, it is possible to extract the viscous heating contribution to capillary pressure loss, and the general validity of the methodology is assessed using the experiments on a series of thermoplastic melts, including polymers of amorphous, crystalline, and filler-reinforced types. The predictions of the viscous model based on the equivalent viscosity are found to be in good to excellent agreement with experimental pressure drops. For all the materials studied, a near material-independent scaling relation between the dimensionless temperature rise (Θ) and the Nahme number (Na) is found, Θ ~ Na0.72, from which the fluid temperature rise due to viscous heating as well as the resultant viscosity change can be predicted.

Nonlinearity and slip behavior of n-hexadecane in large amplitude oscillatory shear flow via nonequilibrium molecular dynamic simulation.

Molecular dynamic simulation is used to investigate the viscoelastic properties of n-hexadecane under oscillatory shear flow. Rheometric simulations of an ultra-thin molecular film are studied and compared with the results of a bulk simulation. Strain amplitude sweep tests at a fixed frequency show that strain thinning (the dynamic modulus monotonically decreases with increasing strain amplitude) exists at extreme strain for both bulk and thin film systems. Fourier analysis is performed to characterize the nonlinear behavior of the viscoelasticity. No even harmonic was found in our study even though wall slip occurs. Furthermore, we show that a Fourier series with odd harmonics can be used to perfectly describe the simulation results by plotting Lissajous loops. Shear wave propagation appears when the frequency is larger than a certain value. Moreover, the molecular orientation and molecular potential energies, including those for bonding potential, intra- and intermolecular van der Waals interactions are plotted against the strain amplitude to examine the changes in the microscopic structures with respect to the macroscopic thermodynamic states.

Molecular structural property and potential energy dependence on nonequilibrium-thermodynamic state point of liquid n-hexadecane under shear.

Extensive computer experiments have been conducted in order to shed light on the macroscopic shear flow behavior of liquid n-hexadecane fluid under isobaric-isothermal conditions through the nonequilibrium molecular dynamic methodology. With respect to shear rates, the accompanying variations in structural properties of the fluid span the microscopic range of understanding from the intrinsic to extrinsic characteristics. As drawn from the average value of bond length and bond angle, the distribution of dihedral angle, and the radius distribution function of intramolecular and intermolecular van der Waals distances, these intrinsic structures change with hardness, except in the situation of extreme shear rates. The shear-induced variation of thermodynamic state curve along with the shear rate studied is shown to consist of both the quasiequilibrium state plateau and the nonequilibrium-thermodynamic state slope. Significantly, the occurrence of nonequilibrium-thermodynamic state behavior is attributed to variations in molecular potential energies, which include bond stretching, bond bending, bond torsion, and intra- and intermolecular van der Waals interactions. To unfold the physical representation of extrinsic structural deformation, under the aggressive influence of a shear flow field, the molecular dimension and appearance can be directly described via the squared radius of gyration and the sphericity angle, R(g)(2) and ϕ, respectively. In addition, a specific orientational order S(x) defines the alignment of the molecules with the flow direction of the x-axis. As a result, at low shear rates, the overall molecules are slightly stretched and shaped in a manner that is increasingly ellipsoidal. Simultaneously, there is an obvious enhancement in the order. In contrast to high shear rates, the molecules spontaneously shrink themselves with a decreased value of R(g)(2), while their shape and order barely vary with an infinite value of ϕ and S(x). It is important to note that under different temperatures and pressures, these three parameters are integrated within a molecular description in response to thermodynamic state variable of density and rheological material function of shear viscosity.

Linear viscoelasticity and thermorheological simplicity of n-hexadecane fluids under oscillatory shear via non-equilibrium molecular dynamics simulations.

A small amplitude oscillatory shear flows with the classic characteristic of a phase shift when using non-equilibrium molecular dynamics simulations for n-hexadecane fluids. In a suitable range of strain amplitude, the fluid possesses significant linear viscoelastic behavior. Non-linear viscoelastic behavior of strain thinning, which means the dynamic modulus monotonously decreased with increasing strain amplitudes, was found at extreme strain amplitudes. Under isobaric conditions, different temperatures strongly affected the range of linear viscoelasticity and the slope of strain thinning. The fluid's phase states, containing solid-, liquid-, and gel-like states, can be distinguished through a criterion of the viscoelastic spectrum. As a result, a particular condition for the viscoelastic behavior of n-hexadecane molecules approaching that of the Rouse chain was obtained. Besides, more importantly, evidence of thermorheologically simple materials was presented in which the relaxation modulus obeys the time-temperature superposition principle. Therefore, using shift factors from the time-temperature superposition principle, the estimated Arrhenius flow activation energy was in good agreement with related experimental values. Furthermore, one relaxation modulus master curve well exhibited both transition and terminal zones. Especially regarding non-equilibrium thermodynamic states, variations in the density, with respect to frequencies, were revealed.

Master curves and radial distribution functions for shear dilatancy of liquid n-hexadecane via nonequilibrium molecular dynamics simulations.

Shear dilatancy, a significant nonlinear behavior of nonequilibrium thermodynamics states, has been observed in nonequilibrium molecular dynamics (NEMD) simulations for liquid n-hexadecane fluid under extreme shear conditions. The existence of shear dilatancy is relevant to the relationship between the imposed shear rate gamma and the critical shear rate gamma(c). Consequently, as gammagamma(c), the intermolecular distance is lengthened substantially by strong shear deformation breaking the equilibrium thermodynamic state so that shear dilatancy takes place. Notably, a characteristic shear rate gamma(m), which depends on the root mean square molecular velocity and the average free molecular distance, is found in nonequilibrium thermodynamics state curves. Studies of the variations in the intermolecular radial distribution function (RDF) with respect to the shear rate provide a direct measure of the variation in the degree of intermolecular separation. Additionally, the variations of the RDF curve in the microscopic regime are consistent with those of the nonequilibrium thermodynamic state in the macroscopic world. By inspecting the overall shape of the RDF curve, it can be readily corroborated that the fluid of interest exists in the liquid state. More importantly, both primary characteristic values, the equilibrium thermodynamic state variable and a particular shear rate of gamma(p), are determined cautiously, with gamma(p) depending on the gamma(m) value and the square root of pressure. Thereby, the nonequilibrium thermodynamic state curves can be normalized as temperature-, pressure-, and density-invariant master curves, formulated by applying the Cross constitutive equation. Clearly, gamma(c) occurs at which a reduced shear rate gamma/gamma(p) approaches 0.1. Furthermore, the trends in the rates of shear dilatancy in both the constant-pressure and constant-volume NEMD systems under isothermal conditions conform to the cyclic rule of pressure, as a function of density and shear rate.

Material functions of liquid n-hexadecane under steady shear via nonequilibrium molecular dynamics simulations: temperature, pressure, and density effects.

Computer experiments of rheology regarding the effects of temperature (T), pressure (P), and density (rho) on steady shear flow material functions, which include viscosity (eta) and first and second normal stress coefficients (psi(1) and psi(2)) depending on shear rate (gamma), have been conducted via nonequilibrium molecular dynamics simulations for liquid n-hexadecane. Straightforwardly, using both characteristic values of a zero-shear-rate viscosity and critical shear rate, eta-gamma flow curves are well normalized to achieve the temperature-, pressure-, and density-invariant master curves, which can be formulary described by the Carreau-Yasuda rheological constitutive equation. Variations in the rate of shear thinning, obviously exhibiting in eta-gamma, psi(1)-gamma, and -psi(2)-gamma relationships, under different T, P, and rho values, are concretely revealed through the power-law model's exponent. More importantly, at low shear rates, the fluid explicitly possesses Newtonian fluidic characteristics according to both manifestations; first and second normal stress differences decay to near zero, while nonequilibrium states are close to equilibrium ones. Significantly, the tendency to vary of the degree of shear thinning in rheology is qualitatively contrary to that of shear dilatancy in thermodynamics. In addition, a convergent transition point is evidently observed in the -psi(2)/psi(1)-gamma curves undergoing dramatic variations, which should be associated with shear dilatancy, as addressed analytically.

Shear thinning and shear dilatancy of liquid n-hexadecane via equilibrium and nonequilibrium molecular dynamics simulations: Temperature, pressure, and density effects.

Equilibrium and nonequilibrium molecular dynamics (MD) simulations have been performed in both isochoric-isothermal (NVT) and isobaric-isothermal (NPT) ensemble systems. Under steady state shearing conditions, thermodynamic states and rheological properties of liquid n-hexadecane molecules have been studied. Between equilibrium and nonequilibrium states, it is important to understand how shear rates (gamma) affect the thermodynamic state variables of temperature, pressure, and density. At lower shear rates of gamma<1 x 10(11) s(-1), the relationships between the thermodynamic variables at nonequilibrium states closely approximate those at equilibrium states, namely, the liquid is very near its Newtonian fluid regime. Conversely, at extreme shear rates of gamma>1 x 10(11) s(-1), specific behavior of shear dilatancy is observed in the variations of nonequilibrium thermodynamic states. Significantly, by analyzing the effects of changes in temperature, pressure, and density on shear flow system, we report a variety of rheological properties including the shear thinning relationship between viscosity and shear rate, zero-shear-rate viscosity, rotational relaxation time, and critical shear rate. In addition, the flow activation energy and the pressure-viscosity coefficient determined through Arrhenius and Barus equations acceptably agree with the related experimental and MD simulation results.