Composites Processing - Fr. Agnelatc.fragnel.ac.in/materials/composites1.pdf · Figure 5: After the...

ME 4210: Manufacturing Processes and

Engineering Prof. J.S. Colton © GIT 2011

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Composites Processing

ver. 1



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Definition

• A microscopic mixture of two or more

different materials. One typically being

the continuous phase (matrix), and the

other being the discontinuous phase

(reinforcement).

• Its properties are strongly dependent on

the composite structure.

• Ductility of matrix combined with

stiffness of reinforcement.



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Ceramic fiber composite

Polymer matrix composite



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Types / Examples

• People

• Trees

• Fiber reinforced matrices

– fiberglass - epoxy

• Particulate reinforced matrices

– tires (carbon black in rubber, but it also has

continuous fibers (steel or polymer belts))



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Fibers/Particles Reinforcement

• Glass

• Kevlar

• Carbon

• Thermoplastics

• Alumina

• Boron

• SiC

• Steel

• Si3N4

• Silica

• Glass beads

• Talc

• Rocks

• Carbon black

• Calcium carbonate



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Reinforcements

• Rovings

– continuous

– bulk

• Continuous strand mat

• Chopped strand mat

• Surface veils



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Matrices

• Protects & separates reinforcement, transmits

forces

• Polymer

– PEEK, epoxy, polyester, polyurethane, rubber

• Metal

– Al, Cu, Ni, Ti

• Ceramic

– glass, cement



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Honeycomb composites



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C-17 Aircraft



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Visby Corvette

Razzle Dazzle Camouflage



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Stealth Ships



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IsoTruss Bike



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Processes

• Hand lay-up

• Vacuum bagging/autoclave

• Compression molding

– SMC/BMC

• Liquid resin molding

• Resin transfer molding



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Processes

• Pultrusion

• Filament winding

• Injection molding

• Thermoplastics processing

• Automated tape laying



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Manual lay-up

• Definition: A process

wherein the application of

resin and reinforcement is

done by hand onto a suitable

mold surface. The resulting

laminate is allowed to cure in

place without further

treatment



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Hand spray-up



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Hand lay-up shop



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Molds



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Mold



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Vacuum bag assembly



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Vacuum bag

Breather

Bleeder



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Lay-up

Material on stiffening

structure

Vacuum bag and

fittings attached



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Autoclave



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Autoclave



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Delta II Rocket



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Delta II rocket



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Can be used with bulk molding compound (BMC)



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Schematic of a compression molding press



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Car parts with Sheet Molding

Compound (SMC) - Prowler



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SMC manufacture using a configuration that can make chopped-fiber

SMC-R; continuous fiber SMC-C; or continuous, random SMC-C/R

material



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Molding process



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Fiber orientation



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Resin transfer molding (RTM) process



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RTM applications

• Auto body panels

• Truck air

deflectors

• Wind blades

• Chemical storage

tanks

• Solar collectors

(40 ft diameter,

36 parts)

• RV components

• Propellers

• Bathtub/shower

units

• Antenna dishes

• Chairs

• Swim pool panels



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Car parts



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RTM automobile structure



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Truck



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Train Compartment

Train Compartment



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Plenum method for making preforms



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Schematic of high-speed RTM process



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SCRIMP – Boat Hulls



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Pultrusion process



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Fiber let-off

Fiber guides

Resin impregnation

Preforming Curing die

Cut-off saw

Puller



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Reinforcements

• Rovings

– continuous

– bulk

• Continuous strand mat

• Chopped strand mat

• Surface veils



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Continuous fiber reinforcement pultusion



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Hollow structure pultrusion process



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RIM (Reaction Injection Molding) pultrusion



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Exploded view of pultruded composite



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Bank of America Building Spire



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Pultruded bridges



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Pultruded

I-beam



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Filament winding



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GT’s machine



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Filament winding machines



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Delta IV Rocket faring

mandrel



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Figure 1: A Veriflex™ cylinder is fabricated.

Figure 2: The cylinder is placed in a clamshell mold,

heated, and blow-molded into a complex-shaped mandrel.

Reusable Mandrels



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Reusable Mandrels

Figure 3: The mandrel is cooled below the transition

temperature resulting in a rigid mandrel.

Figure 4: The mandrel is filament-wound and then cured.

The cure process for the composite does not affect the mandrel.



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Reusable Mandrels

Figure 5: After the composite is cured, the Veriflex™ mandrel is heated

above its activation temperature. The Veriflex™ then becomes pliable and

is removed. The transition temperature does not affect the composite.

Figure 6: The complex part is completed. The cylindrical

Veriflex™ mandrel, which returned to its "memory" shape

while above its transition temperature, can be reused.



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Creel tensioners



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Integral head resin wet-out bath



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Winding pins for low angle winding



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Continuous curing oven



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Layout of a computer-controlled

filament-winding machine



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Gas tanks



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Aerospace parts

F-16 Patriot missile

Soviet missile

Rocket Motor Casings



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Tape laying – 787 fuselage



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Tape laying – 787 fuselage



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Composite motors



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Sporting goods



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Glass epoxy filament-wound 9-foot-diameter by 55-foot-

long assembled railway tank car



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Pipe machine and cure oven



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Light pole



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Thermoplastics processing



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Injection molding

Clamp Mold

Hopper

Barrel



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Injection molding

hopper

heaters

barrel

screw

nozzle clamp

mold

cavity

pellets

motor /

drive

throat



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Roll forming



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Roll-formed part



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Matched die forming

sample and

holder alignment pins

adjustment bolts

weights



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Press forming of LDF (long discontinuous fibers)

Formed component

after trimming

Clamp and

thermoform Transfer into

heated dies Heat material



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Compression molding



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Compression molding sequence



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Hydroforming



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Diaphragm forming



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Diaphragm forming



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Vacuum forming in autoclave



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Stretch forming



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Tape laying



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Automated Tow Placement

- Thermoplastics



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Robotic thermoplastic ATP machine

NASA Langley



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Filament winding thermoplastic ATP

machines



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Filament winding thermoset ATP

machine



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Large ATP machine



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Typical parts



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