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Pinholes in surface after resin infusion

2010-11-16

Please help me before i go insane... After every infusion i do (practcing on glass using carbon fibre and plain weave e glass) There are small gaps between every tow in the weave. I have tried everything i can think of to stop this. I am using carbon that is stored in bubble wrap, epoxy infusion resin, i acheive full vac and no loss of vacuum. As i do it on glass i can see where the problem lies.... During infusion it works perfectly, but as soon as i clamp the feed line small voids form in the weave. I also de gas the resin for 10 minutes first. Any help would be very much appreciated.

How do you define full vacuum? The only meaningful definition, in this case, is absolute pressure - not gauge pressure. Absolute pressure is measured relative to a perfect vacuum (zero is a perfect vacuum), and requires a special gauge like a U-tube manometer. Gauge pressure is measured relative to ambient atmospheric pressure (zero means no vacuum), and is what most gauges measure.

There are two reasons for your pin holes.
1. Residual air in fibers tows that were encapsulated by resin flowing through the weave openings. After resin plugs the vacuum port, no more air can be removed. Capillary action causes resin in the weave to wick into the tows, displacing the air into the weave openings. The solutions are use a better vacuum (so there is no residual air to trap), or to slow down the infusion so that the wicking of resin into the tows closely follows the flow front through the weave (so the resin can push the residual air out the vacuum port).
2. You may be boiling the resin by applying too much vacuum after you close the resin inlet. Resins will always have some volatiles (including the resin itself). After closing the resin inlet and the vacuum line is full of resin the vacuum should be reduced to 10 inHg. This provides 10 inHg of compaction pressure on the fibers while maintaining 20 inHg on the resin during cure.

I've spent the past 8 months doing a lot of trial and error to learn VARTM.  At one point I think I was having the same problem as you.  Are you using a vacuum bag around the sheet of glass?  When you clamp off the inlet do you have epoxy in the vacuum tube going to your pump?  I am wondering if your epoxy is going up the creases of your bag and right into the pump line.  At that point any air leaks causes the epoxy to percolate in your part and causes pin holes and voids.  If you have any creases in your vacuum bag the same thing will happen, the epoxy will follow the path of least resistance and go right to the outlet.  This may cause voids because the epoxy does not flow through the fabric.  Rather than using resin flow, make your part a little oversize and surround it with a perimeter of breather material on peel ply.  Pull the vacuum on the breather material and infuse from the lowest point or the center.  You can also do some fabric flow tests to see which point is the best to pull from and to infuse from using fiberglass and some other liquid - I've used coffee before so I can see the flow pattern.  Another thing to consider is that if you see the epoxy percolating in your exit tube - there is a leak. Also, look at the geometry of your part.  I like to set things up so that I use the vacuum to pull a void in the fabric and let gravity fill things up.  If you keep your exit end higher and keep enough epoxy in your feed tube you'll usually be okay.


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