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Resin infusion is a pressure-gradient-driven composite manufacturing process in which the liquid resin is driven to flow through and fill in the void space of a porous composite preform prior to the heat treatment for resin solidification. It usually is a great challenge to design both the infusion system and the infusion process meeting the manufacturing requirements, especially for large-scale components of aircraft and wind turbine blades. Aiming at addressing the key concerns about flow fronts and air bubble entrapment, the present study proposes a modelling framework of the multiphase flow of resin and air in a dual scale porous medium, i.e. a composite preform. A finite strain formulation is discussed for the fluid–solid interaction during an infusion process. The present study bridges the gap between the microscopic observation and the macroscopic modelling by using the averaging method and first principle method, which sheds new light on the high-fidelity finite element modelling.

Finite Strain Modelling for Multiphase Flow in Dual Scale Porous Media During Resin Infusion Process