introduction to composites manufacturing · • resin transfer molding • pultrusion •...
TRANSCRIPT
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Introduction to Composites Manufacturing
Alfred C. LoosMechanical Engineering Department
Michigan State UniversityEast Lansing, MI 48824-1226
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Objectives
• To combine reinforcing fibers with a resin matrix to form a structure with the desired properties.
• Optimal processing will result in composite parts:– Fully consolidated– Void free– Uniform matrix properties– Desired fiber/resin content– “Best” properties– Processed in the shortest amount of time
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Glass Fiber
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PREPREGGING TECHNIQUES
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Prepreg
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Wetlay Paper Making Process
U.S. Patent 5,409,573
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Dewatered Non-Woven Mat
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COMMOM FABRICATION METHODS
• Vacuum Bag - Autoclave Molding• Compression Molding• Filament Winding• Resin Transfer Molding• Pultrusion• Thermoforming
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Tape Lay-Up Machine
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Autoclave
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Molded Radio Box
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Automotive Gas Tank Heat Shield
•25% E-glass
•PET RBR Flake
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Filament Winding Machine
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Resin Transfer Molding (RTM)– Closed mold process, reduced volatile emissions– Near net-shape molded parts – Close dimensional tolerances– Smooth surface finish on both sides of part– Cores, ribs and inserts can be encapsulated into part– Requires expensive matched metal heated tools
Rigid Metal Mold
Fiber PreformResin
Resin Injection Pot
Piston
Rigid Base
Rigid Lid Air Port
Rigid Metal Mold
Fiber PreformResin
Resin Injection Pot
Piston
Rigid Base
Rigid Lid Air Port
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Textile Material Forms
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Textile Material Forms
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F-22 Raptor Program
• Sine-Wave Spar Panel• 20 % reduction in manufacturing cost
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Vacuum Assisted Resin Transfer Molding (VARTM)
– Upper half of metal mold replaced by vacuum bag.– Atmospheric pressure provides both the resin driving
force and the preform compaction force.– Distribution medium is used to facilitate the resin flow
(SCRIMP®).– Room temperature process.
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Wind Turbine Blade
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Contest 55 Sailing Yacht• Hull Dimensions
−
16.4 m long−
4.5 m wide−
2.5 m high
http://www.polyworx.com
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Pultrusion Process
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Pultrusion Machine
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Pultrusion Machine
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Pultruded ProductsPultruded Rod Pultruded Structural Shapes
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Pultruded Products
Composite Building Panel System Handrail Systems
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Thermoforming Process
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Thermoformed Composite Parts
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