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Composite Manufacturing Processes

Composite Manufacturing Processes. Dr. Yiping Qiu. Composite Manufacturing Processes. Thermoset composites Short fiber reinforced Continuous fiber reinforced Prepreg resin transfer Thermoplastic composites Commingle Impregnated. Composite Manufacturing Processes. Processes:

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Composite Manufacturing Processes

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  1. Composite Manufacturing Processes Dr. Yiping Qiu

  2. Composite Manufacturing Processes • Thermoset composites • Short fiber reinforced • Continuous fiber reinforced • Prepreg • resin transfer • Thermoplastic composites • Commingle • Impregnated

  3. Composite Manufacturing Processes • Processes: • Hand Lay-up • Pre-preg forming • Pressure molding • Vacuum bagging • Filament winding

  4. Composite Manufacturing Processes • Processes: • Pultrusion • Spray method • Sheet molding • Bulk molding • Resin transfer molding

  5. Hand lay-up

  6. Hand lay-up • Advantages: • low cost tools • versatile: wide range of products • Disadvantages: • time consuming • easy to form air bubbles and disorientation of fibers • inconsistency

  7. Prepreg forming • Machine

  8. Prepreg forming

  9. Prepreg forming • Advantages: • orientation of fibers can be changed • consistent • high productivity • Disadvantages: • continuous process needs more customers • limited shelf life • delamination

  10. Prepreg forming

  11. Pressure molding

  12. Pressure molding • Advantages: • wide range of shapes • integrate parts • consistency • structural stability • relatively simple • Disadvantages: • high cost of machine • time consuming to heat up, cool down and curing • expensive molds (strong materials required) • no intricate parts • large volume of products

  13. Vacuum bagging • Process

  14. Vacuum bagging • Advantages: • simple design • any fiber/matrix combination • ok with cheap mold material • better quality for the cost • Disadvantages: • cannot be heated up too much • breeder clothe has to be replaced frequently • low pressure (760 mm Hg the most) • slowest speed • inconsistency

  15. Filament winding

  16. Filament winding

  17. Filament winding

  18. Filament winding products • Compressed air tanks • High-pressure CO2 tanks and bottles • Water softener systems • Rescue air tanks • Sail boat masts • Compressed Natural Gas tanks • Defense/Aerospace systems • Lightpoles

  19. Filament winding • Advantages: • using existing textile processes. • quick, easy to handle package. • parts can have huge size. • Disadvantages: • spinning speed is limited due to resin penetration and splashing, traveler speed and yarn breakage. • curing by heat is not easy to apply. • shape of the products limited (only cylindrical possible).

  20. Pultrusion

  21. Pultrusion

  22. Pultrusion • Advantages: • Automated processes. • High speed. • Versatile cross-sectional shape. • Continuous reinforcement. • Disadvantages: • Die can be easily messed up. • Expensive die. • Mainly thermoset matrix.

  23. Spray method

  24. Spray method • Advantages: • Continuous process • Any materials can be used as mold. • Error can be corrected by re-spraying. • Disadvantages: • Slow. • inconsistency. • No control of fiber orientation. • Only one side finished. • Environmental unfriendly.

  25. Sheet molding

  26. Sheet molding • Advantages • High productivity thus inexpensive • consistency • Disadvantages • low volume fraction. • Only board can be made.

  27. Bulk molding

  28. Bulk molding • Advantages • Highest volume fraction for short fiber reinforced composites (50%) • Good mechanical properties • Finish can be applied • Inserts and attachments possible • Disadvantages • High temperature and high pressure • Random fiber orientation • Cannot be used for intricate parts • Staple fibers only.

  29. Resin transfer molding http://www.plastech.co.uk/Mtrtm.html

  30. Resin transfer molding • Advantages • Components will have good surface finish on both sides • Selective reinforcement and accurate fiber management is achievable • Ability to build-in fiber volume fraction loadings up to 65% • Uniformity of thickness and fiber loading, uniform shrinkage • Inserts may be incorporated into moldings • Tooling costs comparatively low • Uses only low pressure injection • Low volatile emission during processing • Ability to produce near net shape moldings • Process can be automated, resulting in higher production rates • Ability to mould complex structural and hollow shapes • Low resultant voids • Ability to achieve from 0.5mm to 90mm laminate thickness • Disadvantages • waste some material (spill) • curing time long • hard for intricate parts

  31. Vacuum Assisted Resin Transfer Molding • http://www.futuremediacreations.com/technoire/vartm.htm

  32. Vacuum Assisted Resin Transfer Molding • Advantages? • … • Disadvantages?

  33. Filament Placement

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