Composites Processing ver. 1 1
Definition A microscopic mixture of two or more different materials. One typically being the continuous phase (matrix), and the other being the discontinuous phase (reinforcement). Its properties are strongly dependent d on the composite structure. Ductility of matrix combined with stiffness of reinforcement. 2
Ceramic fiber composite Polymer matrix composite 3
People Trees Types / Examples Fiber reinforced matrices fiberglass - epoxy Particulate reinforced matrices tires (carbon black in rubber, but it also has continuous fibers (steel or polymer belts)) 4
Fibers/Particles Reinforcement Glass Kevlar Carbon Thermoplastics Alumina Boron SiC Steel Silica Glass beads Talc Rocks Carbon black Calcium carbonate Si 3 N 4 5
Reinforcements Rovings continuous bulk Continuous strand mat Chopped strand mat Surface veils 6
Matrices Protects & separates reinforcement, transmits forces Polymer PEEK, epoxy, polyester, polyurethane, rubber Metal Al, Cu, Ni, Ti Ceramic glass, cement 7
Honeycomb composites 8
C-17 Aircraft 9
Visby Corvette 10
IsoTruss Bike 11
Hand lay-up Processes Vacuum bagging/autoclave Compression molding SMC/BMC Liquid resin molding Resin transfer molding 12
Processes Pultrusion Filament winding Injection molding Thermoplastics processing Automated tape laying 13
Manual lay-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 14
Hand spray-up 15
Hand lay-up shop 16
Molds 17
Mold 18
Vacuum bag assembly 19
Vacuum bag Breather Bleeder 20
Lay-up Material ilon stiffening i structure Vacuum bag and fittings attached 21
Autoclave 22
Autoclave 23
Delta II Rocket 24
Delta II rocket 25
Can be used with bulk molding compound (BMC) 26
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Schematic of a compression molding press 28
Car parts with Sheet Molding Compound (SMC) - Prowler 29
SMC manufacture using a configuration that can make chopped-fiber SMC-R; continuous fiber SMC-C; or continuous, random SMC-C/R material 30
Molding process 31
Fiber orientation 32
Resin transfer molding (RTM) process 33
RTM applications Auto body panels Truck air deflectors Wind blades Chemical storage tanks Solar collectors (40 ft diameter, 36 parts) RV components Propellers Bathtub/shower units Antenna dishes Chairs Swim pool panels 34
Car parts 35
RTM automobile structure t 36
Truck 37
Train Compartment 38
Train Compartment 39
Plenum method for making preforms 40
Schematic of high-speed RTM process 41
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SCRIMP Boat Hulls 43
Pultrusion process 44
Fiber let-off Preforming Curing die Fiber guides Cut-off saw Resin impregnation Puller 45
Reinforcements Rovings continuous bulk Continuous strand mat Chopped strand mat Surface veils 46
Continuous fiber reinforcement pultusion 47
Hollow structure pultrusion process 48
RIM (Reaction Injection Molding) pultrusion 49
Exploded view of pultruded composite 50
Bank of America Building Spire 51
Pultruded bridges 52
Pultruded I-beam 53
Filament winding 54
GT s machine 55
Filament winding machines 56
Delta IV Rocket faring mandrel 57
Reusable Mandrels Figure 1: A Veriflex e cylinder is fabricated. Figure 2: The cylinder is placed in a clamshell mold, heated, and blow-molded into a complex-shaped mandrel. 58
Reusable Mandrels Figure 3: The mandrel is cooled below the transition temperature resulting in a rigid mandrel. Figure 4: The mandrel is filament-wound and then cured. The cure process for the composite does not affect the mandrel. 59
Reusable Mandrels Figure 5: After the composite is cured, the Veriflex mandrel is heated above its activation ation temperature. re The Veriflex 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, which returned to its "memory" shape while above its transition temperature, can be reused. 60
Creel tensioners 61
Integral head resin wet-out bath 62
Winding pins for low angle winding 63
Continuous curing oven 64
Layout of a computer-controlled filament-winding machine 65
Gas tanks 66
Aerospace parts F-16 Patriot missile Soviet missile 67
Tape laying 787 fuselage 68
Tape laying 787 fuselage 69
Composite motors 70
Sporting goods 71
Glass epoxy filament-wound 9-foot-diameter by 55-foot- long assembled railway tank car 72
Pipe machine and cure oven 73
Light pole 74
Thermoplastics processing 75
Injection molding Clamp Mold Barrel Hopper 76
Injection molding clamp nozzle pellets barrel hopper throat mold cavity screw heaters motor / drive 77
Roll forming 78
Roll-formed part 79
Matched die forming adjustment bolts sample and holder alignment pins weights 80
Press forming of LDF (long discontinuous fibers) Heat material Transfer into heated dies Clamp and thermoform Formed component after trimming 81
Compression molding 82
Compression molding sequence 83
Hydroforming 84
Diaphragm forming 85
Diaphragm forming 86
Vacuum forming in autoclave 87
Stretch forming 88
Tape laying 89
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Automated Tow Placement - Thermoplastics 91
Robotic thermoplastic ATP machine NASA Langley 92
Filament winding thermoplastic ATP machines 93
Filament winding thermoset ATP machine 94
Large ATP machine 95
Typical parts 96
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