Advanced Composite Processes

Dr. S. Nagaraja Rao

Principal, PG Section, G.T.T.C, Mysore

Advanced composite Processes

Common feature to all polymeric composite processes: Combining resin, curing agent, reinforcing fiber, and in some cases a solvent.

Heat and pressure: Shape and "cure" the mixture into a finished part.

Resin : Hold the fibers together, protect them & transfer the load to the fibers in composite part. Curing agent/ hardener: Acts as a catalyst and helps in curing the resin to a hard plastic. Reinforcing fiber: Imparts strength and other required properties

Major Processes
Processes: Automated Manual Combined

Basic process types

Formulation: Mixing of resin, curing agent, and any other component required May involve adding the components manually into a small mixing vessel or In case of larger processes components may be pumped into a mixing vessel

Prepregging

Resin and curing agent mixture are impregnated into the reinforcing fiber. Prepregs main forms: 1. woven fabrics 2. roving 3. unidirectional tape. Fabrics and tapes -continuous rolls in widths up to 72 inches and lengths up to several hundred feet. Fabric or tape thickness constitutes one ply in the construction of a multi-ply lay-up. Impregnated roving is wound onto cores or bobbins prepreg must be stored in a refrigerator or freezer until use cold storage prevents the chemical reaction from occurring prematurely. Prepreg materials used in advanced composite industry- aircraft and aerospace.

PREPREG MANUFACTURE

Open Molding processes

part being manufactured is exposed to the atmosphere. worker typically handles the part manually Higher potential for exposure The resin mixture may be a liquid being formed onto a reinforcing material or prepreg material being formed for final cure.

Open Molding process

Closed Molding processes

All or part of the manufacture takes place in a closed vessel or chamber. The liquid resin mixture or prepreg material may be handled or formed manually into the container for the curing step. Liquid resin mixtures pumped into the container, usually a mold of some type, for the curing step.

Sequential or batch processes

Manufacture of a single part at a time, in sequence. This type of process is usually required: Part being made is small complex in shape curing phase is critical finishing work must be minimized small number of parts

Continuous processes
are

typically automated to some degree and are used to produce larger numbers of identical parts relatively quickly. These processes are typified by pumping of the resin mixture into the mold, followed by closed curing.

Resins
The

resin systems used to manufacture advanced composites are of two basic types: thermosetting and thermoplastic. Thermosetting resins predominate today, while thermoplastics have only a minor role in advanced composites manufacture.

Thermosets
Thermoset resins require addition of a curing agent or hardener and impregnation onto a reinforcing material, followed by a curing step to produce a cured or finished part. Once cured, the part cannot be changed or reformed, except for finishing. Common thermosets : Epoxies Polyurethanes Phenolic and amino resins Bismaleimides (BMI, polyimides) Polyamides

EPOXIES

Epoxies: Most commonly used in today's PMC industry. Basic epoxy compounds: reaction product of epichlorohydrin and bisphenol-A. Epoxy compounds are also referred to as glycidyl compounds. Types of epoxy compounds : glycidyl ethers (or diglycidyl ethers), glycidyl esters, and glycidyl amines.

Several of these compounds are reactive diluents and are sometimes added to the basic resin to modify performance characteristics.
The epoxy molecule can also be expanded or cross-linked with other molecules to form a wide variety of resin products, each with distinct performance characteristics. These resins range from low-viscosity liquids to high-molecular weight solids. Typically they are high-viscosity liquids.

Curing agent or hardener:

They control the reaction rate

Determine the performance characteristics of the finished part.

These compounds act as catalysts for the reaction

Curing agents :

Aromatic amines. 4,4'-methylene-dianiline (MDA) 4,4'-sulfonyldianiline (DDS).

Other types of curing agents&Resins

Aliphatic and cycloaliphatic amines polyaminoamides amides anhydrides. Note:The choice of curing agent depends on the cure and performance characteristics desired for the finished part. Polyurethanes are another group of resins used in advanced composite processes. These compounds are formed by reacting the polyol component with an isocyanate compound, typically toluene diisocyanate (TDI); methylene diisocyanate (MDI) and hexamethylene diisocyanate (HDI) are also widely used.

RESINS AND CURINGS(CONTD)

Phenolic

and amino resins are another group of PMC resins. They are used extensively in aircraft interiors becaosue of their exceptional low smoke and heat release properties in the event of a fire. The bismaleimides and polyamides are relative newcomers to the advanced composite industry and are used for high temperature applications.

AUTOCLAVE CURING & BONDING

Prepreg

method adopts both vacuum bagging & autoclave for consolidation & curing. Autoclave Pressure Temperature (Heat)

AUTOCLAVE CURING

AUTOCLAVE CURING & BONDING

Advantages
Superior

Products Complex parts can be produced Problems: Heat loss Control Costly

Filament Winding
Winding

Methods Wet Dry Post Impregnation

Filament Winding

Winding Types
Hoop Circumferential Radial Helical Axial Polar

Process of Winding
A

continuous wire or tape or mat of fibrous material is dipped in a resin bath and wound on a mandrel in the desired orientation and desired thickness.

Resins used
Epoxy

--- most common Polyester --- most common Phenolic Silicon Thermoplastics

Reinforcement
E-glass S-glass

Carbon
Aramids Graphite Combinations

Examples of combination
Graphite for longitudinal stiffness, Fiberglass to resist hoop direction. Carbon for strength, Aramid for impact strength.

Desirable Factors
Proper

control of resin viscosity, consistency Temperature Tension control Proper shape of mandrels Rotational speed of mandrels Post curing

Characteristics of filament wound parts

Voids

minimum Flexibility Joints between the composite and metal can be made easily

Advantages

Varying size High strength in desired directions Less material wastage Forming shapes easy Panels and fittings can be included during winding Parts with high pressure ratings can be made Continuous process and thus faster production Overall production cost is lower

PULTRUSION

Continuous reinforcement fibers are impregnated with resin shaped by drawing through a die.

Types of die:
Fixed High pressure Floating Low & Medium pressures Multiple

PULTRUSION

PULTRUSION

Applications

Building panels Electrical insulators Supports & panels for truck trailers Door support for automobiles Ladder rails Pressure tanks (Trunk portion) Aircraft flooring Rods, Stringers, Stiffness for aircraft and automobile leaf springs (Shock absorbers)

Advantages (contd.)

Storage tanks Pipes Chimney liners Lightening arresters Springs Shafts Wind turbine blades