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03 Manufacturing

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9 views22 pages

03 Manufacturing

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hmh4pak
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© © All Rights Reserved
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Structural Composites Design

(Composite Materials in Civil Infrastructure)


III. Manufacturing Processes

Pizhong Qiao (Chiao), Ph.D., P.E., SECB


Department of Civil and Environmental Engineering
Washington State University
Pullman, WA 99164-2910
Phone: (509) 335-5183; Fax: (509) 335-7632
Email: Qiao@wsu.edu
3.1 Selection of Manufacturing Process

Based on requirements for:

• type of matrix and fibers


• temperature to form and cure the matrix
• geometry of the part
• cost effectiveness

The material and the part (shape) are designed


concurrently
3.2 Types of Composite Manufacturing
• Lay-up: Hand lay-up, Spray lay-up, Prepreg Lay-Up, Automatic tape
lay-up
• Prepregs
• Compression molding: Resin injection molding, Incremental
molding, Stamp molding, High-pressure compression molding,
Injection molding
• Bag molding: Pressure bag molding, Vacuum bag molding
• Autoclave molding: a modification of pressure bag and vacuum bag
molding
• Filament winding: Helical winding, Hoop (circumferential) winding
• Resin transfer molding (RTM): Flexible RTM (FRTM), Continuous
RTM (CRTM), Vacuum assisted RTM (VARTM), High-speed RTM
(HSRTM), etc.
• Pultrusion
• Molding compounds: SMC (sheet molding compound), BMC (bulk
molding compound)
3.3 General Operations in Processing Polymer
Matrix Composites

1. Fiber placement with orientation preferences


2. Impregnation of the fibers with the resin (fiber wetting)
3. Consolidation of the impregnated fibers
4. Cure of solidification of the polymer
5. Extraction from the mold
6. Finishing operation.
3.4 Manufacturing Process (1) – Lay-up

Hand Lay-Up (Fig. 3.1 in the textbook, p.44)


1. Prepare a mold: the mold surface must be coated and thoroughly
polished first, a mold agent is then generally applied using a
spray. After the release agent is completely dry, a gelcoat is
applied by spray or brush
2. Manually place the dry fiber reinforcement in the mold which is
coated with catalyzed and accelerated resin
3. Apply (pour) resin
4. Press (roll) the wet composite
with hand rollers
5. Repeat steps 2-4 until the
desired thickness is achieved.
6. Cure the layered structure
3.4 Manufacturing Process (2) – Lay-up

Automatic tape-laying machine


Spray lay-up
3.4 Manufacturing Process (3) - Prepregs
Prepregs:
• Thin sheets of fiber impregnated with predetermined amounts of
uniformly distributed polymer matrix
• The fiber volume fraction is high (50%~80%) to obtain the high
mechanical properties
• An improvement in working conditions resulting from the removal
of handling resins and the toxic vapors
• Automation of the lamination possible with an automated tape-
laying machine, allowing the products cost to be reduced

Schematic diagram of manufacturing a prepreg


3.4 Manufacturing Process (4) – Bag molding
Prepreg Lay-Up:
• Similar to Conventional Hand Lay-up, except that the
impregnation of fibers is made prior to molding.

Bag Molding
• A uniform pressure through pressure bag, vacuum bag (Fig. 3.2
in the textbook, p.48), or autoclave processing (See next
Figure), is applied to improve consolidation of the fibers and
removal of the excess resin, air, and volatiles from the matrix

Vacuum Bagging: Fabrication Lab – Fabricating a Composite


Plate

Autoclave Processing: High pressure and High temperature


3.4 Manufacturing Process (5) – Bag molding

Pressure bagging

Vacuum bagging
3.4 Manufacturing Process (6) – Bag molding

Autoclave processing
3.4 Manufacturing Process (7) – Compression molding
Compression Molding (Fig. 3.3 in the textbook, p.50)
• Male and female metal dies to form the mold
• Charge the mold with fiber and resin
• Apply hydraulic press (both heat and high pressure)
• Eject the part from the mold
• Bulk molding compound (BMC) and Sheet molding
compound (SMC) are commonly used in compression
molding
3.4 Manufacturing Process (8) – Compression molding

Resin injection molding

Injection molding
3.4 Manufacturing Process (9) – Compression molding

Sheet molding compound (SMC)

Bulk molding compound (BMC)


3.4 Manufacturing Process (10) – Resin transfer molding
Resin Transfer Molding (Fig. 3.4 in the textbook, p.51)
• Place dry fiber reinforcement in the mold
• Close the mold
• Pump liquid resin into the mold through the inlet, and
allow air to escape through the outlet
• Once the mold is full, seal the mold inlets and outlets
• Apply heat to cure the resin
• Open the mold and remove the composite part

• Vacuum Assisted Resin Injection Molding (VARIM) -


SCRIMP: Apply vacuum in the outlet of the mold and
draw resin into mold by vacuum only (see Application on
Manufacturing a Fiberglass Composite Bridge Deck using
SCRIMP, Composite Technology, 1999: Handout).
3.4 Manufacturing Process (11) – Resin transfer molding
Resin Transfer Molding (Fig. 3.4 in the textbook, p.51)
3.4 Manufacturing Process (12) – Resin transfer molding

VARTM
HSRTM
3.4 Manufacturing Process (13) – Pultrusion
Pultrusion (Fig. 3.5 in the textbook, p.54)

• A continuous and efficient manufacturing process to


manufacture constant cross-section shapes of any length (visit
Creative Pultrutions, Inc. website:
http://www.creativepultrusions.com/)
• Most suitable for thermosetting resins that cure without
producing a condensation by-product (polyester or epoxy)

1. Pull fibers from Creel and mat racks with preforming guides
2. Enter dry reinforcement into the injection chamber where they
were wetted by resin
3. Wet reinforcement travels through the heated die
4. FRP shape is cured and cut into the desired length
3.4 Manufacturing Process (14) – Pultrusion

Pultrusion (Fig. 3.5 in the textbook, p.54)


3.4 Manufacturing Process (15) – Filament winding
Filament Winding (Fig. 3.6 in the textbook, p. 57)
• Shapes of surfaces of revolution (e.g., pipes, cylinders, and
spheres)
• High fiber volume fractions (up to 80%) can be obtained by
controlling the winding tension on the fibers

1. Pull fibers from creel and mat racks with preforming guides by
winder
2. Pass the fibers through a resin bath which they are wetted
3. Wind the wetted onto a rotated mandrel with certain fiber
orientation
4. Remove the mandrel from the winder and place in a gas-fired or
electric oven

*** Read Chapter 3 in the textbook ***


3.4 Manufacturing Process (16) – Filament winding
Filament Winding (Fig. 3.6 in the textbook, p. 57)
Advantages:
1. The process may be automated and provides high production
rates
2. Highest-strength products are obtained because of fiber
placement control
3. Versatility of sizes
4. Control of strength in different direction possible
Disadvantages:
1. Winding reverse curvatures is different
2. Winding at low angles (parallel to rotational axis) is different
3. Complex (double-curvature) shapes are difficult to obtain
4. Poor external surface
3.4 Manufacturing Process (17) – Filament winding
Filament Winding (Fig. 3.6 in the textbook, p. 57)
3.4 Manufacturing Process (18) – Filament winding

Filament Winding (Fig. 3.6 in the textbook, p. 57)

Circumferential winding
Helical winding

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