composites processing

8/14/2019 Composites Processing

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ME 4210: Manufacturing Processes andEngineering Prof. J.S. Colton GIT 2009

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Definition A microscopic mixture of two or more

.the continuous phase (matrix), and the

(reinforcement). ts propert es are strong y epen ent on

the composite structure. Ductility of matrix combined with

stiffness of reinforcement.


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P l Trees

fiberglass - epoxy Particulate reinforced matrices

tires (carbon black in rubber, but it also hascontinuous fibers (steel or polymer belts))


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Glass

Kevlar Carbon

Silica Glass beads

Thermoplastics Alumina

Talc Rocks

Boron

Carbon black

Steel


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Reinforcements

R vin continuous

Chopped strand mat

Surface veils


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Protects & separates reinforcement, transmitsorces

Polymer , epoxy, po yester, po yuret ane, ru er

Metal , u, , Ceramic

g ass, cemen


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Processes Hand lay-up

acuum agg ng autoc ave Compression molding SMC/BMC

Li i r in m l in Resin transfer molding


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Pultrusion

Injection molding ermop as cs process ng Automated tape laying


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- Definition: A rocess

wherein the application ofresin and reinforcement isdone by hand onto a suitablemold surface. The resultinglaminate is allowed to cure inplace without furthertreatment


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Molds


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Bleeder


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La -u

Material on stiffeningstructure

Vacuum bag andfittings attached


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Autoclave


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ME 4210: Manufacturing Processes andEngineering Prof. J.S. Colton GIT 2009 23


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Can be used with bulk moldin com ound BMC



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Schematic of a compression molding press



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Car parts with Sheet MoldingCompound (SMC) - Prowler



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SMC manufacture using a configuration that can make chopped-fiberSMC-R; continuous fiber SMC-C; or continuous, random SMC-C/R

material



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Resin transfer molding (RTM) process



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RTM li i n Auto body panels RV components

Truck airdeflectors Propellers Wind blades

units

tanks

Chairs

(40 ft diameter, Swim pool panels



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au omo e s ruc ure



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Train Compartment



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Train Com artment



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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 rocess


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- Curing die

Fiber guidesCut-off saw


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Resin impregnation Puller


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Reinforcements

R vin

continuous

Chopped strand mat

Surface veilsME 4210: Manufacturing Processes and

Engineering Prof. J.S. Colton GIT 200946


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Continuous fiber reinforcement pultusion


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w u u u u


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RIM (Reaction Injection Molding) pultrusion


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Exploded view of pultruded composite


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Pultruded brid es


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Pultruded-


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Filament windin


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GTs machine


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Filament windin machines


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Delta IV Rocket farinmandrel


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Reusable Mandrels


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Reusable Mandrels

Fi ure 1: A Veriflex c linder is fabricated.


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

R bl M d l


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Reusable Mandrels

temperature resulting in a rigid mandrel.

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

Reusable Mandrels


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Reusable Mandrels

Figure 5: After the composite is cured, the Veriflex mandrel is heateda ove s ac va on empera ure. e er ex en ecomes p a e anis removed. The transition temperature does not affect the composite.

Figure 6: The complex part is completed. The cylindrical " "


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,while above its transition temperature, can be reused.


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Layout of a computer-controlled


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Aerospace parts


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p p

F-16 Patriot missile


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S ortin oods


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S ortin oods


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


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ME 4210: Manufacturing Processes and


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Li ht ole


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Clamp Mold

Hopper

Barrel



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hopper

barrelnozzleclamp

pellets

throat

heaterscavit motor /

drive



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Roll-formed part


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adjustment bolts

sample andholder

alignment pins

weights



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Press formin of LDF


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(long discontinuous fibers)

Formed componentafter trimming

Clamp andthermoform

Transfer intoheated diesHeat material



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Hydroforming


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Diaphragm forming


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Vacuum forming in autoclave


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Automated Tow Placementh l i


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- Thermoplastics



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NASA Langley



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Filament winding thermoplastic ATP


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mac nes



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Filament winding thermoset ATP

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machine



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