vacuum bag resin infusioncam.bue.edu.eg/presentations/16 may 2011/02-session... · resin used in...
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Bakir Plastics Co.1
Vacuum Bag Resin Infusion
An Innovative Fabricating Method For Composites
Bakir Plastics Co.2
Terminology
Fabrication Steps
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion
Bakir Plastics Co.3
Terminology
Composite Material – A material that is fabricated from two or
more material components of different
natures resulting in a new material with
properties different from the initial
materials.
Matrix - Is the component material containing all
other Component materials within its limits.
It usually starts as a thermosetting polymer
liquid or a thermoplastic solid.
(Also Ceramics, Carbon and metals).
Bakir Plastics Co.4
Terminology … continued
Thermosetting Plastics - The group of plastics that once set and
formed cannot be reshaped by heat.
Examples are: U.Polyesters, Epoxides,
Phenolics (liquid and powder). PURs,
Furan. Also powder Melamine and Urea
Fordmaldhyde.
Thermoplastic - The group of plastics that can be formed
and reformed by heat.
Examples are: PP and PA.
Bakir Plastics Co.5
Terminology … continued
Reinforcing Fibres – Is the main additive to the matrix that
together form the composite material. They
are made of: Glass, Plastics, Carbon,
Ceramics, Metal, and Natural Fibres.
They come in many forms.
Laminates - Simultaneous plies/layers of reinforcing
fibres that forms the wall thickness of the
composite. Each and every laminate can
posses similar or different properties.
Bakir Plastics Co.6
Terminology … continued
Additives - Materials that are added to the
matrix to influence its properties,
appearance, cost …. etc.
Core Material - Is a material of higher thickness and lower
density included between two composite
skins to notably increase its bending
strength with little increase in weight.
Examples are: Foams (PVC - PET - PUR
… etc.) - Honeycombs - Void cores.
Bakir Plastics Co.7
Terminology … continued
Cure - Is the chemical reaction or setting changing the polymer from the liquid into the solid state.
Cure Time - Is the time for the liquid polymer to set into a solid matrix.
Cure System - In the case of “Unsaturated Polyester”, is a group of one or more additives that causes the polymer to cure during the required period. They are called promoters, accelerators, catalysts & peroxides. In the case of “Epoxies and PURs” its the hardener.
Bakir Plastics Co.8
Terminology … continued
Pot Life - Is the life-time of the liquid polymer to set in
the dispensing container starting from the
time of mixing with the cure system.
Vacuum Bag - Is a film that contains all the Vacuum
Infusion System within. It is tightly sealed
with addhesive tapes against any air leaks.
Bakir Plastics Co.9
Terminology … continued
Perforated Release Film – A film that is placed in direct contact the
composite materials. It has the ability not to
stick to the cured resin matrix and allows
the resin to penetrate it from the bleeder to
the laminate reinforcements.
Breather /Bleeder/ - A fabric with a double function. It is used for
air suction through the vacuum pipe and
for resin distribution.
Bakir Plastics Co.10
Fabrication Steps Single Wall Wind Turbine Small Blade
Step 1 - Mould preparation & waxing
Bakir Plastics Co.11
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 2 - Glassfiber Laminates are placed dry
Bakir Plastics Co.12
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 3 - The Perforated Release film is applied
Bakir Plastics Co.13
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 4 - Breather Bleeder cloth is placed
Bakir Plastics Co.14
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 5 - Vacuum Bag and pipes are sealed with an adhesive tape
Bakir Plastics Co.15
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 6 - Vacuum Bag is tested for air leaks
Bakir Plastics Co.16
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 7 - Resin is drawn into the laminates using vacuum
Bakir Plastics Co.17
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 8 - Start of removal of infusion material set after part curing
Bakir Plastics Co.18
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 9 - Removing the bagging film.
Bakir Plastics Co.19
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 10 - Removing the release film and breather
Bakir Plastics Co.20
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 11 - Removing the composite blade first half
Bakir Plastics Co.21
Fabrication Steps Single Wall Wind Turbine Small Blade … continued
Step 12 - The two produced blade halvesready to assemble together
Bakir Plastics Co.22
Fabrication Steps Double Skin Sandwich Panel
Step 1 - Glassfiber Laminates for the outer skin are placed dry
Bakir Plastics Co.23
Fabrication Steps Double Skin Sandwich Panel … continued
Step 2 - Perforated PUR Sheets are placed
Bakir Plastics Co.24
Fabrication Steps Double Skin Sandwich Panel … continued
Step 3 - Foam Core is placed next
Bakir Plastics Co.25
Fabrication Steps Double Skin Sandwich Panel … continued
Step 4 - The Inner Skin Glassfiber Laminates are placed
Bakir Plastics Co.26
Fabrication Steps Double Skin Sandwich Panel … continued
Step 5 - The Perforated Release film is applied
Bakir Plastics Co.27
Fabrication Steps Double Skin Sandwich Panel … continued
Step 6 - Breather / Bleeder cloth is placed.
Bakir Plastics Co.28
Fabrication Steps Double Skin Sandwich Panel … continued
Step 7 - Vacuum Bag is cut and prepared with the adhesive tape
Bakir Plastics Co.29
Fabrication Steps Double Skin Sandwich Panel … continued
Step 8 - Vacuum Bag and pipes are sealed with an adhesive tape and tested
Bakir Plastics Co.30
Fabrication Steps Double Skin Sandwich Panel … continued
Step 9 - Vacuum is applied and tested for air leaks
Bakir Plastics Co.31
Fabrication Steps Double Skin Sandwich Panel … continued
Step 10a - Resin is drawn into the laminates using vacuum.
Bakir Plastics Co.32
Fabrication Steps Double Skin Sandwich Panel … continued
Step 10b - Resin is spreading more
Bakir Plastics Co.33
Fabrication Steps Double Skin Sandwich Panel … continued
Step 10c - Resin is spreading further more
Bakir Plastics Co.34
Fabrication Steps Double Skin Sandwich Panel … continued
Step 10d - And more
Bakir Plastics Co.35
Fabrication Steps Double Skin Sandwich Panel … continued
Step 11 - The produced Sandwich Panel
Bakir Plastics Co.36
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion
1- Method Description
Hand lay-up
Is the traditional wet laminating
method.
Resin infusion
Uses a sealed plastic film to
achieve a net vacuum on dry
fabric in order to draw resin
through that fabric
Bakir Plastics Co.37
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion … continued
2- Fiber to resin ratio
Hand lay-up
Inacurate as the resin is applied
manually resulting in an
oversaturated state of the laminate.
A typical hand lay-up usually
results in excess of double the
resin used in resin infusion. And it
is difficult to remove the excess
resin
Resin infusion
Better fiber-to-resin ratio. Resin alone is very brittle, so any excess will actually weaken the part. The reinforcement materials starts dry, but compressed, when the resin is introduced. Any excess resin will eventually be sucked into the vacuum line. As a result, only the minimum amount of resin is introduced. This lowers weight, increases strength and maximizes the properties of composite.
Bakir Plastics Co.38
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion … continued
3- Mechanical Properties
Hand lay-up
Mechanical properties are
pedictable and suitable for all sizes
of final products with performance
unaffected by excess resin weight
Resin infusion
Much higher mechanical properties /
specific strength, due to the usage of
the optimum resin to fiber ratio.
Bakir Plastics Co.39
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion … continued
4- Product Quality
Hand lay-up
The human variable is of great
influence.
Resin infusion
Constant high quality. However, a
correct infusion strategy is
necessary.
Bakir Plastics Co.40
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion … continued
5- Quality Risks
Hand lay-up
Straightforward. When something
goes wrong, one still can end with
this part, still suitable, however not
as good as being vacuum bagged.
Resin infusion
Due to the complexity and ease of
error in the infusion strategy, it is
very easy to destroy a part. Once
infusion begins, there is little that can
be done to correct a strategy error.
Bakir Plastics Co.41
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion … continued
6- Materials Handling
Hand lay-up
Not easy and even messy.
Resin infusion
Easy. All materials are used in a dry
and clean condition.
Bakir Plastics Co.42
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion … continued
7- Size of Job
Hand lay-up
Larger lay-ups are only possible
with the help of a lot of extra
hands.
Resin infusion
Unlimited. Even large lay-ups are
possible for a single-handed builder.
Bakir Plastics Co.43
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion … continued
8- Costs
Hand lay-up
Initial low er capital costs but higher
labour cost .
Resin infusion
Extra costs for vacuum pump,
vacuum bag, sealant tape, tubing,
connectors, release film and resin
distribution material.
Bakir Plastics Co.44
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion … continued
9- Simultaneous sandwich laminating
Hand lay-up
Difficult and messy. Needs highly
trained labour and adequate resins
formulation otherwise voids and
poor adhesion with the lamiate
skins will occur.
Resin infusion
Easier, due to the laying of the
materials in its dry forms. The resin
is introduced by suction filling all the
voids and resulting in full adhesion
with the skins.
Bakir Plastics Co.45
Comparison Between Hand Lay-up And Vacuum Bag Resin Infusion … continued
10- Health
Hand lay-up
Due to the nature of the process
using open moulds, precautions
has to be taken to avoid health
hazards due to evolving fumes,
splashes or spills.
Resin infusion
Cleaner process. Vacuum infusion
provides a cleaner, safer and friendlier
work environment. There are no brushes
or rollers, and therefore no splashing,
spattering or dripping on onerself. There
are almost no resin fumes to contend with.
It is merely mixing the resin and pour it
into a bucket, from whence it is sucked in
fully automated fashion into the bag
covered laminates.