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Composite Materials Manufacturing

Composite Materials Manufacturing. 정분방. Introduction. Definition: a material composed of 2 or more constituents Reinforcement (e.g., Fibers) matrix ( e.g.,epoxy ) Advantages High strength and stiffness Low weight ratio Material can be designed in addition to the structure

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Composite Materials Manufacturing

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  1. Composite MaterialsManufacturing 정분방

  2. Introduction • Definition: a material composed of 2 or more constituents • Reinforcement (e.g., Fibers) • matrix(e.g.,epoxy) • Advantages • High strength and stiffness • Low weight ratio • Material can be designed in addition to the structure • Can manufacture structures and eliminate joints

  3. Applications • Aerospace industry • Sporting goods • Automotive • Construction

  4. Costs of composite manufacture • Material costs -- higher for composites • Constituent materials (e.g., fibers and resin) • Processing costs -- embedding fibers in matrix • Design costs -- lower for composites • Can reduce the number of parts in a complex assembly by designing the material in combination with the structure

  5. Material Forms and manufacturing • Objectives of material production • assemble fibers • impregnate resin • shape product • cure resin

  6. Sheet Molding Compound (SMC) • Chopped glass fiber added to polyester resin mixture

  7. Manufacturing - Filament Winding • Highly automated • low manufacturing costs if high throughput • e.g., Glass fiber pipe, sailboard masts • the only manufacturing technique suitable for makingcertain specialized structures, such as pressure vessels.

  8. Prepregs • Prepreg and prepreg layup • “prepreg” - partially cured mixture of fiber and resin • Unidirectional prepreg tape with paper backing • wound on spools • Cut and stacked • Curing conditions • Typical temperature and pressure in autoclave is 120-200C, 100 psi

  9. Manufacturing - Layups compression molding vacuum bagging

  10. Autoclave Advantages good for building prototype parts and smallquantity runs Limitations labor intensive, high labor cost

  11. Resin transfer molding (RTM) • Dry-fiber preform placed in a closed mold, resin injected into mold, then cured • High cost, tooling design is complex

  12. Manufacturing - Pultrusion • Fiber and matrix are pulled through a die, like extrusion of metals -- assembles fibers, impregnates the resin, shapes the product, and cures the resin in one step. • Example:Fishing rods Advantages: simple low-cost, continuous, and automatic process. Limitations: the axial direction, fiber angles 0°, not suit for tapered and complex shapes

  13. Pultrusion

  14. Thank you

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