Composites Processing

Composites Processing
ver. 1
ME 4210: Manufacturing Processes and 1

Engineering Prof. J.S. Colton © GIT 2009
Definition
• A microscopic mixture of two or more
different materials.
materials One typically being
the continuous phase (matrix), and the
other being the discontinuous phase
(reinforcement).
• Its
It properties
ti are strongly
t l dependent
d d t on
the composite structure.
• Ductility of matrix combined with
stiffness of reinforcement.
Ceramic fiber composite
Polymer matrix composite

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))

Fibers/Particles Reinforcement
• Glass
• Kevlar • Silica
• Carbon • Glass beads
• Thermoplastics • Talc
• Alumina • Rocks
• Boron • Carbon black
• SiC • Calcium carbonate
• Steel
• Si3N4
Reinforcements
• Rovings
– continuous
– bulk
• Continuous strand mat

• Chopped strand mat
• Surface veils
Matrices
• Protects & separates reinforcement, transmits
forces
• Polymer
– PEEK,
PEEK epoxy, polyester,
l polyurethane,
l h rubber
bb
• Metal
– Al,
Al CCu, Ni
Ni, Ti
• Ceramic
– glass,
glass cement

Honeycomb composites

C 17 Aircraft
C-17

Visby Corvette

IsoTruss Bike

Processes
• Hand lay-up
• Vacuum
V b
bagging/autoclave
i / l
• Compression molding
– SMC/BMC
• Liquid resin molding
• Resin transfer molding

Processes
• Pultrusion
• Filament winding
• Injection molding
• Th
Thermoplastics
l ti processing
i
• Automated tape laying

Manual lay
lay-up
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

Hand spray
spray-up
up

Hand lay
lay-up
up shop

Molds

Mold

Vacuum bag assembly

Vacuum bag
Breather
Bleeder

Lay-up
y p
Material
i l on stiffening
iff i
structure
Vacuum bag and

fittings attached

Autoclave

Autoclave

Delta II Rocket

Delta II rocket

Can be used with bulk molding
g compound
p ((BMC))

Schematic of a compression molding press

Car parts with Sheet Molding
Compound (SMC) - Prowler

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

Molding process

Fiber orientation

Resin transfer molding (RTM) process

RTM applications
• Auto body panels • RV components
• Truck air • Propellers
deflectors • Bathtub/shower
• Wind blades units
• Chemical storage • Antenna dishes
tanks • Chairs
• Solar collectors • Swim pool panels
(40 ft diameter,
36 parts)
Car parts

RTM automobile
t bil structure
t t

Truck

Train Compartment

Train Compartment
p

Plenum method for making preforms

Schematic of high-speed RTM process

SCRIMP – Boat Hulls

Pultrusion process
p

Fiber let-off
let off Preforming
Curing die
Cut-off saw
Fiber guides

Resin impregnation
Engineering Prof. J.S. Colton © GIT 2009 Puller
Reinforcements
• Rovings
– continuous
– bulk
• Continuous strand mat

• Chopped strand mat
• Surface veils
Continuous fiber reinforcement pultusion

Hollow structure pultrusion process

RIM (Reaction Injection Molding) pultrusion

Exploded view of pultruded composite

Bank of America Building Spire

Pultruded bridges
g

Pultruded
I-beam

Filament winding
g

GT’s machine

Filament winding
g machines

Delta IV Rocket faring
g
mandrel

Reusable Mandrels
Figure
gu e 1: A Veriflex™
e e cy
cylinder
de is
s fabricated.
ab cated
Figure 2: The cylinder is placed in a clamshell mold

mold,
heated, and blow-molded into a complex-shaped mandrel.
Reusable Mandrels
Figure 3: The mandrel is cooled below the transition

temperature resulting in a rigid mandrel.
Figure 4: The mandrel is filament-wound

filament wound and then cured
cured.
The cure process for the composite does not affect the mandrel.
Reusable Mandrels
Figure 5: After the composite is cured, the Veriflex™ mandrel is heated

abo e its activation
above acti ation temperature.
temperat re The Veriflex™
Verifle ™ 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
mandrel, which returned to its "memory"
memory shape
while above its transition temperature, can be reused.
Creel tensioners

Integral head resin wet
wet-out
out bath

Winding pins for low angle winding

Continuous curing oven

Layout of a computer-controlled
filament winding machine
filament-winding

Gas tanks

Aerospace parts
F-16 Patriot missile
Soviet missile
Tape laying – 787 fuselage

Tape laying – 787 fuselage

Composite motors

Sporting
p gggoods

Glass epoxy filament-wound 9-foot-diameter by 55-foot-
long assembled railway tank car

Pipe machine and cure oven

Light
g p pole

Thermoplastics processing

Injection molding
Clamp
l Mold
ld Barrell
Hopper

Injection molding
pellets hopper
clamp nozzle barrel
throat
mold
cavityy screw heaters motor /

drive

Roll forming

Roll-formed part

Matched die forming
adjustment bolts
sample and alignment pins

holder
weights

Press forming
g of LDF
(long discontinuous fibers)
Transfer into Clamp and Formed component

Heat material heated dies thermoform after trimming

Compression molding

Compression molding sequence

Hydroforming

Diaphragm forming

Diaphragm forming

Vacuum forming in autoclave

Stretch forming

Tape laying

Automated Tow Placement
- Thermoplastics

Robotic thermoplastic ATP machine
NASA Langley

Filament winding thermoplastic ATP
machines
hi

Filament winding thermoset ATP
machine

Large ATP machine

Typical parts


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Composites Processing

ME 4210: Manufacturing Processes and 1

Polymer matrix composite

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• Continuous strand mat

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Vacuum bag and

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• Continuous strand mat

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Figure 2: The cylinder is placed in a clamshell mold

Figure 3: The mandrel is cooled below the transition

Figure 4: The mandrel is filament-wound

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

Figure 6: The complex part is completed. The cylindrical

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