This numerical study investigates heat generation and cure during the unsaturated flow of thermosetting resins in woven, stitched or braided fiber mats during mold filling in liquid composite molding (LCM), a popular technology to manufacture polymer-matrix composites. This study is relevant to those mats, which can be characterized as a dual-scale porous medium. An iterative, control-volume approach, based on energy and cure balances in a two-layer model representing fiber tows and gaps between tows, is used for developing discretized equations for average temperatures and cures in the tows and gaps respectively. A significant difference in the temperatures and cures of the gap and tow regions is observed. The proposed model deviates significantly from the conventional single-scale model used in most LCM simulations and highlights the need to adopt a different approach in modeling cure and temperature in dual-scale fiber mats.

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