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ME 4210: Manufacturing Processes andEngineering Prof. J.S. Colton GIT 2009
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Definition A microscopic mixture of two or more
.the continuous phase (matrix), and the
(reinforcement). ts propert es are strong y epen ent on
the composite structure. Ductility of matrix combined with
stiffness of reinforcement.
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P l Trees
fiberglass - epoxy Particulate reinforced matrices
tires (carbon black in rubber, but it also hascontinuous fibers (steel or polymer belts))
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Glass
Kevlar Carbon
Silica Glass beads
Thermoplastics Alumina
Talc Rocks
Boron
Carbon black
Steel
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Reinforcements
R vin continuous
Chopped strand mat
Surface veils
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Protects & separates reinforcement, transmitsorces
Polymer , epoxy, po yester, po yuret ane, ru er
Metal , u, , Ceramic
g ass, cemen
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Processes Hand lay-up
acuum agg ng autoc ave Compression molding SMC/BMC
Li i r in m l in Resin transfer molding
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Pultrusion
Injection molding ermop as cs process ng Automated tape laying
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- Definition: A rocess
wherein the application ofresin and reinforcement isdone by hand onto a suitablemold surface. The resultinglaminate is allowed to cure inplace without furthertreatment
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Molds
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Bleeder
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La -u
Material on stiffeningstructure
Vacuum bag andfittings attached
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Autoclave
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Can be used with bulk moldin com ound BMC
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Schematic of a compression molding press
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Car parts with Sheet MoldingCompound (SMC) - Prowler
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SMC manufacture using a configuration that can make chopped-fiberSMC-R; continuous fiber SMC-C; or continuous, random SMC-C/R
material
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Resin transfer molding (RTM) process
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RTM li i n Auto body panels RV components
Truck airdeflectors Propellers Wind blades
units
tanks
Chairs
(40 ft diameter, Swim pool panels
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au omo e s ruc ure
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Train Compartment
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Train Com artment
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Plenum method for making preforms
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Schematic of high-speed RTM process
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SCRIMP Boat Hulls
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Pultrusion rocess
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- Curing die
Fiber guidesCut-off saw
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Resin impregnation Puller
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Reinforcements
R vin
continuous
Chopped strand mat
Surface veilsME 4210: Manufacturing Processes and
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Continuous fiber reinforcement pultusion
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w u u u u
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RIM (Reaction Injection Molding) pultrusion
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Exploded view of pultruded composite
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Pultruded brid es
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Pultruded-
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Filament windin
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GTs machine
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Filament windin machines
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Delta IV Rocket farinmandrel
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Reusable Mandrels
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Reusable Mandrels
Fi ure 1: A Veriflex c linder is fabricated.
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,heated, and blow-molded into a complex-shaped mandrel.
R bl M d l
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Reusable Mandrels
temperature resulting in a rigid mandrel.
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.The cure process for the composite does not affect the mandrel.
Reusable Mandrels
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Reusable Mandrels
Figure 5: After the composite is cured, the Veriflex mandrel is heateda ove s ac va on empera ure. e er ex en ecomes p a e anis removed. The transition temperature does not affect the composite.
Figure 6: The complex part is completed. The cylindrical " "
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,while above its transition temperature, can be reused.
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Layout of a computer-controlled
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Aerospace parts
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p p
F-16 Patriot missile
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S ortin oods
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S ortin oods
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Glass epoxy filament-wound 9-foot-diameter by 55-foot-
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Li ht ole
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Clamp Mold
Hopper
Barrel
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hopper
barrelnozzleclamp
pellets
throat
heaterscavit motor /
drive
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Roll-formed part
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adjustment bolts
sample andholder
alignment pins
weights
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Press formin of LDF
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(long discontinuous fibers)
Formed componentafter trimming
Clamp andthermoform
Transfer intoheated diesHeat material
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Hydroforming
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Diaphragm forming
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Vacuum forming in autoclave
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Automated Tow Placementh l i
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- Thermoplastics
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NASA Langley
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Filament winding thermoplastic ATP
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mac nes
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Filament winding thermoset ATP
hi
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machine
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