An efficient ultrasound vibration strategy for suppressing intra-bundle pores and regulating pore morphology in carbon fiber-reinforced composites

The competitive resin flow between intra- and inter-bundles, always causes the generation of intra-bundle pores during resin transfer molding (RTM), thereby weakening composite mechanical performance. Accordingly, an ultrasound vibration strategy is originally developed to efficiently suppress and improve the spatial morphology and distribution of intra-bundle pores in RTM manufacturing. The effects of ultrasound vibration on the spatial evolution of intra-bundle pores are systematically investigated, furthermore, the suppression mechanisms of intra-bundle pores are revealed. Additionally, an empirical model that predicts porosity under ultrasound vibration, is established and well validated for the developed ultrasound vibration strategy, which provides a feasible path for effectively manufacturing composites. X-ray micro-computed tomography experiments verify that applying a short period of ultrasound vibration balances the dual-scale flow by regulating the modified capillary number, thereby significantly reducing porosity by up to 59.4 %. Numerical analyses indicate that the acoustic cavitation and acoustic flow induced by the ultrasound vibration, facilitate the collapse and transverse migration of larger bubbles, thereby remarkably suppressing the connected pores and larger pores. In particular, the ultrasound vibration strategy completely removes the pores larger than 300 μm. Besides, the collective effects of vibration, compression, and shear forces contribute to forming near-circular pores, which are beneficial for ensuring the expected mechanical performance of composites.