A Systematic Characterization Approach for Vacuum Bag Only Prepregs towards an Accurate Process Design

Aerospace-grade composite parts can be manufactured using Vacuum Bag Only prepregs through an accurate process design. Quality in the desired part can be realized by following process modeling, process optimization, and validation, which strongly depend on a primary and systematic material characterization methodology of the prepreg system and material constitutive behavior. The present study introduces a systematic characterization approach of a Vacuum Bag Only prepreg by covering the relevant material properties in an integrated manner with the process mechanisms of fluid flow, consolidation, and heat transfer. The characterization recipe is practiced under the categories of (i) resin system, (ii) fiber architecture, and (iii) thermal behavior. First, empirical models are successively developed for the cure-kinetics, glass transition temperature, and viscosity for the resin system. Then, the fiber architecture of the uncured prepreg system is identified with X-ray tomography to obtain the air permeability. Finally, the thermal characteristics of the prepreg and its constituents are experimentally characterized by adopting a novel specimen preparation technique for the specific heat capacity and thermal conductivity. Thus, this systematic approach is designed to provide the material data to process modeling with the motivation of a robust and integrated Vacuum Bag Only process design.

Successful Barrier Enhancement Application of Epoxy Based Resin for Multiple Casing to Casing Annuli Having Tight Injectivity - Case Study from Saudi Arabian Peninsula

This study describes the approach used for enhancing the well integrity that was compromised with gas flow through a casing-casing annulus (CCA). Extremely tight injectivity at a CCA demands a solid free solution which not only can be injected but also resist high differential pressures to provide a long-term barrier in CCA. In this paper a successful leak remediation using an epoxy resin system helped the operator save a well and restart its production. Several pressure tests were conducted for identifying an extremely tight casing leak which was causing formation gas travelling to surface through the annulus. This issue required the customer to look for an efficient remedial solution to seal off the gas leakage and regain productivity. Due to the extremely low injectivity, a conventional cement squeeze or any solid laden particle-based squeeze approach was prone to fail. Alternatively, a tailored solid free epoxy resin system was placed in the annulus using an unconventional placement technique resulted in barrier enhancement and helped the operator place the well back into production. For a mature well flowing through 7 × 9 5/8‑in. and 9 5/8 × 13 3/8‑in., a tailored epoxy-based resin system formulation was placed in the well bore with modified surface operations procedures which helped in eliminating current annular pressure to regain well integrity and production. Remedial operations were performed from the surface by squeezing to seal off the gas coming from the annulus. A Tailored design derived from rigorous lab testing and perfect field execution resulted in CCA pressure remediation in a single attempt of the treatment injection, proving that the concept of using a solids-free resin to enhance existing deteriorated barriers is a reliable method. This epoxy resin system helped the operator to regain the well integrity and production in the shortest time without expensive well intervention operations. Epoxy resin based systems have been identified as a novel solution to remediate barrier integrity for well construction and workover operations, hence such case histories with enhanced operations procedures are helpful in increasing awareness of the benefits that can be attained in challenging high-pressure, low-injectivity environments, and can improve well economics.

Deep Penetration Resin Systems Overcome Annular Gas Migration: Case History

Well Integrity is a critical compliance requirement during oil and gas operations. Abandonment procedures must ensure that all hydrocarbon sources are properly isolated and effective barriers are placed. This paper describes the use of resin systems to isolate annular gas migration identified during the Obiwan – 1 well abandonment in Colombia. The main challenge was to select and design fluid systems capable to fill tight spaces and isolate the annular channel. Resin systems are high-strength, elastic polymers which act as dependable barriers to isolate fluid flow. They can be designed as a solid-free, pure liquid or may contain solids (cement with a formulated percent of resin). Solid-free formulations are ideal for remedial operations, such as isolating annular gas. Acoustic logging enabled identification of the influx zones. Annular isolation was achieved by executing two cementing remedial operations using the bradenhead squeeze technique. A tailored resin system was selected to deliver the proper barrier addressing the influx zones after injectivity tests were performed in each interval. For the first intervention a solids-free resin system was used, and for the second one a resin-cement composite system was applied. During cementing remedial operations, it was determined that the resin systems were able to achieve deep penetration into the channels more readily and form a seal. The correct system was selected for each case, and during execution, the required volume was injected to intersect and properly isolate the annular gas channel. As a result, the tailored resin systems isolated the gas channel eliminating annular pressure and gas migration to surface. In addition, a post remedial operation acoustic log indicated that the influx zones were successfully isolated. Well abandonment was accomplished according to country regulatory requirements and delivered dependable barriers both annular and interior pipe sections. Use of resin to repair channels of this type exhibited a higher success rate and improved reliability in comparison to conventional particulate-laden fluids, which helps to decrease costs for additional remedial treatments.

Extraction behaviors of aqueous PEG impregnated resin system in terms of impregnation stability and recovery via protein impregnated resin interactions on bovine serum albumin

Background Current advances in biotechnology have been looked at as alternative approaches towards the limited product recovery due to time- and cost-consuming drawbacks on the conventional purification methods. This study aimed to purify bovine serum albumin (BSA) as an exemplary target product using an aqueous impregnated resin system (AIRS). This method implies the concept of hydrophobicity of polymer that impregnated into the resins and driven by electrostatic attractions and hydrophilicity of aqueous salt solution to extract the target product. Methods The extraction behaviors of impregnation in terms of stability and adsorption kinetics via protein-aqueous polymer impregnated resin were studied. Impregnation stability was determined by the leaching factor of polyethylene glycol (PEG). The major factors such as PEG molecular weights and concentration, pH of aqueous salt solution, extraction methods (sonication and agitation) and types of adsorbent material and concentration of aqueous salt phase influencing on partitioning of biomolecule were also investigated. Results For impregnation stability, the leaching factor for Amberlite XAD4 did not exceed 1%. The scanning electron microscopy (SEM) image analysis of Amberlite XAD4 attributes the structural changes with impregnation of resins. For adsorption kinetics, Freundlich adsorption isotherm with the highest R2 value (0.95) gives an indication of favorable adsorption process. Performance of AIRS impregnated with 40% (w/w) of PEG 2000 was found better than aqueous-two phase system (ATPS) by yielding the highest recovery of BSA (53.72%). The outcomes of this study propound the scope for the application of AIRS in purification of biomolecules.

Crosslinking, Mechanical Properties, and Antimicrobial Activity of Photocurable Diacrylate Urethane/ZnO-Ag Nanocomposite Coating

In this article, ZnO-Ag nanohybrids were chemically synthesized in the aqueous medium by reducing silver nitrate with sodium borohydride NaBH4. These nanohybrids were then homogeneously dispersed into the diacrylate urethane/1,6-hexanediol diacrylate resin system at a content of 2 wt%. The structural morphology, mechanical resistances, and crosslinking of the as-prepared nanocomposite coating (nanocoating) were evaluated. The antimicrobial characteristic was tested by keeping track of the lag-log growth phase of E. coli bacteria in the coating existence among cell cultures. The obtained data indicated that the nanohybrids added into the UV curing diacrylate urethane matrices had significantly increased the abrasion resistance, relative hardness, and conversion of the acrylate groups of the nanocoating. In addition, the antibacterial test revealed that the nanocoating had good antibacterial property against E. coli, whereas for the pure coating (without ZnO-Ag nanoparticles), there was no antibacterial activity observed.

Dry Fibre Placement: The Influence of Process Parameters on Mechanical Laminate Properties and Infusion Behaviour

Within the dry fibre placement (DFP) process, spread and pre-bindered carbon fibre rovings are automatically processed into dry textile preforms using 2-D and 3-D laying systems. The aim was to automate existing hand lay-up processes, reducing the complexity, increasing robustness, and facilitating the handling of the DFP technology. Process reliability, low waste rates, and flexible production are demonstrated. In this publication, the influences of the process parameters, 2 mm wide gaps and the percentage of 90° plies in the laminate, are investigated with regard to the mechanical properties, the permeability, and the infusion times in the preform z-direction (thickness). The effects on stiffness and strength are compared for several use cases. An approach to determine the infusion times as a function of the laminate thickness, the ply structure, and 2 mm wide gaps is demonstrated and analysed using vacuum-assisted process (VAP) infusion tests. The investigations are performed with carbon fibre tows (24 k), a reactive epoxy-based binder system, and a thermoset infusion resin system.

Research on the composition of UV curing modified compounds for 3D printing based on HyperChem simulation

The precursor conversion method provides the possibility of 3D printing ceramic materials, and the resin system with polysilazane as the precursor is expected to prepare high-performance ceramic materials for aviation. In this paper, the UV curing reaction system of polysilazane for 3D printing is taken as the research object, and hyperchem8.0 software is used as the research means. The model construction, chemical bond energy calculation, reaction enthalpy calculation and other modules in the software are used to simulate and predict the reaction process and mechanism of UV curing, which provides a theoretical basis for the selection and optimization of the subsequent UV curing reaction system for 3D printing.