Particle filtration and distribution during the liquid composite molding process for manufacturing particles containing composite materials

The effects of major process parameters on particle filtration and distribution were investigated by using newly developed microscopic methodology using an electron probe micro-analyzer and numerical simulation. The mapping results indicated that well-dispersed particles were distributed uniformly in the inter-tow and intra-tow regions. Agglomerates were likely to be filtered at the boundary or inside of the fiber bundle. The results of quantitative analyses showed particle concentrations in the inter-tow region to be uniform throughout the composite part, whereas the intra-tow concentrations varied according to particle size and fiber orientation. The poor dispersion state of the CNT-Ag particles resulted in quite irregular distributions. A high volume fraction of the fiber preform resulted in a lower particle concentration inside the fiber tow. Numerical analysis of the filtration of large clusters of particles indicated that filtration occurred in the initial stage of the injection process at the tow boundaries.