Overview of composite manufacturing technologies
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1 Composite technology BMEGEPT AGE1 Overview of composite manufacturing technologies Gergely Czél Spring 2018
2 Composites- Structure Lamina, ply, layer Matrix Fibre Interface Laminate Stacking/lay-up sequence BMEGEPT AGA1 Composite technology Gergely Czél / 49
3 Composite manufacturing- basics Reinforcing fibres High elastic modulus High strength GF, CF, AF Forming technique: In-situ polymerisation (crosslinking) of matrix (design freedom in geometry) Adhesion Composite High strength High modulus Fatigue resistance density Brittle Matrix Impact resistant Chemically resistant Thermoset (crosslinked) polymer resin UP, EP, VE BMEGEPT AGA1 Composite technology Gergely Czél / 49
4 Wet lay-up BMEGEPT AGA1 Composite technology Gergely Czél / 49
5 Wet lay-up summary Cycle time Production run Material cost Investment Tooling cost Labour cost Geometrical flexibility Property flexibility Finishing need Quality control H&S risk Wet lay-up High Short High for detail, high for large size Medium, poor properties High High BMEGEPT AGA1 Composite technology Gergely Czél / 49
6 Wet lay-up applications BMEGEPT AGA1 Composite technology Gergely Czél / 49
7 Wet lay-up applications BMEGEPT AGA1 Composite technology Gergely Czél / 49
8 Spray-up process BMEGEPT AGA1 Composite technology Gergely Czél / 49
9 Spray-up summary Cycle time Production run Material cost Investment Tooling cost Labour cost Geometrical flexibility Property flexibility Finishing need Quality control H&S risk Spray-up High Short Medium Medium for detail, high for large size Minimum, poor properties High Medium High BMEGEPT AGA1 Composite technology Gergely Czél / 49
10 Spray-up applications BMEGEPT AGA1 Composite technology Gergely Czél / 49
11 Resin transfer/liquid moulding BMEGEPT AGA1 Composite technology Gergely Czél / 49
12 RTM applications BMEGEPT AGA1 Composite technology Gergely Czél / 49
13 Resin transfer/liquid moulding summary Cycle time Production run Material cost Investment Tooling cost Labour cost Geometrical flexibility Property flexibility Finishing need Quality control H&S risk RTM Medium- long Medium-high Medium High High for detail, low for size Medium- high Medium-high BMEGEPT AGA1 Composite technology Gergely Czél / 49
14 Vacuum infusion moulding BMEGEPT AGA1 Composite technology Gergely Czél / 49
15 VIM- applications BMEGEPT AGA1 Composite technology Gergely Czél / 49
16 Vacuum infusion moulding summary Cycle time Production run Material cost Investment Tooling cost Labour cost Geometrical flexibility Property flexibility Finishing need Quality control H&S risk VIM Long Short- medium Medium-low Medium Medium for detail, High for size Medium- low Medium-high Medium BMEGEPT AGA1 Composite technology Gergely Czél / 49
17 Pultrusion BMEGEPT AGA1 Composite technology Gergely Czél / 49
18 Pultrusion- applications BMEGEPT AGA1 Composite technology Gergely Czél / 49
19 Pultrusion summary Cycle time Production run Material cost Investment Tooling cost Labour cost Geometrical flexibility Property flexibility Finishing need Quality control H&S risk Pultrusion Continuous Long Medium- high Medium- high Medium- high Medium- low BMEGEPT AGA1 Composite technology Gergely Czél / 49
20 Filament winding BMEGEPT AGA1 Composite technology Gergely Czél / 49
21 Filament winding- applications BMEGEPT AGA1 Composite technology Gergely Czél / 49
22 Filament winding summary Cycle time Production run Material cost Investment Tooling cost Labour cost Geometrical flexibility Property flexibility Finishing need Quality control H&S risk Pultrusion Long Medium- long -high Medium- high - high - medium Medium-high Medium- high High BMEGEPT AGA1 Composite technology Gergely Czél / 49
23 Centrifugal casting BMEGEPT AGA1 Composite technology Gergely Czél / 49
24 Centrifugal casting summary Cycle time Production run Material cost Investment Tooling cost Labour cost Geometrical flexibility Property flexibility Finishing need Quality control H&S risk Pultrusion Long Medium- long Medium Medium Medium- high Medium BMEGEPT AGA1 Composite technology Gergely Czél / 49
25 Compression moulding- Mixing BMC: Bulk Moulding Compound SMC: Sheet Moulding Compound BMEGEPT AGA1 Composite technology Gergely Czél / 49
26 Compression moulding BMC SMC Weighing Pressure F Preform cutting Heat watch?v=vl3wayzk-is BMEGEPT AGA1 Composite technology Gergely Czél / 49
27 Compression moulding- applications BMEGEPT AGA1 Composite technology Gergely Czél / 49
28 Compression moulding summary Cycle time Production run Material cost Investment Tooling cost Labour cost Geometrical flexibility Property flexibility Finishing need Quality control H&S risk Pultrusion Short Long Medium- high High High - medium BMC: high for detail SMC: high for size -medium High BMEGEPT AGA1 Composite technology Gergely Czél / 49
29 Prepreg manufacturing Matrix (low viscosity) Fibres Impregnation Maturing i.e. increasing matrix viscosity, (max. 40 C), B-stage Prepreg Intermediate product which contains pre-mixed two part matrix resin and fibres and all other components needed to preserve this product ready for lay-up and curing at elevated temperature and pressure to form a solid cross-linked structure BMEGEPT AGA1 Composite technology Gergely Czél / 49
30 Prepreg manufacturing Hot melt route BMEGEPT AGA1 Composite technology Gergely Czél / 49
31 Prepreg manufacturing Film transfer route BMEGEPT AGA1 Composite technology Gergely Czél / 49
32 Prepreg manufacturing Solution route BMEGEPT AGA1 Composite technology Gergely Czél / 49
33 Prepreg lay-up and bagging om/watch?v=t22vjlhw xya&nohtml5=false BMEGEPT AGA1 Composite technology Gergely Czél / 49
34 Prepreg curing- Autoclave Elevated temp. ( C) High pressure up to 10 Bar atch?v=u4brwi5xi0g&nohtm l5=false BMEGEPT AGA1 Composite technology Gergely Czél / 49
35 Prepreg curing- Oven BMEGEPT AGA1 Composite technology Gergely Czél / 49
36 Autoclave curing of prepregs Open mould, Indirect/Dry technology Typically used with epoxy resin and UD or bi-axial fabric carbon (glass) fibre reinforcement Additives: Essential: Reactive (Initiators, catalysts, accelerators, inhibitors to control long shelf life and fast, complete cure.), Optional: Fillers (Usually mineral powders), Antistatic agents, Colorants etc. Controlled resin consolidation and resin ratio Shelf life is limited: 1 year@-18 C, 6 months@0-5 C, days@room temp., ~50 defrost cycles Refrigerated storage is expensive One part, rigid mould with vacuum bag Lay-up is labour and skill intensive Tack is a key property at lay-up Expensive consumables Excellent mechanical properties, high fibre volume fraction Good surface finish and precision on one side High level process and quality control achievable Moderate design freedom in size, large freedom in mechanical design Typical products: from F1 components to aircraft wings, high performance composite parts BMEGEPT AGA1 Composite technology Gergely Czél / 49
37 Prepreg products BMEGEPT AGA1 Composite technology Gergely Czél / 49
38 Autoclave curing of prepregs summary Prepreg/autoclave Cycle time Production run Material cost Investment Tooling cost Labour cost Geometrical flexibility Property flexibility Finishing need Quality control H&S risk Long Short- medium High High - medium High Medium High -medium High BMEGEPT AGA1 Composite technology Gergely Czél / 49
39 Thank you for your attention! Dr Gergely Czél
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