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Composite Manufacturing Processes
Composite Manufacturing Processes
Yiping Qiu
Prepreg
resin transfer
Thermoplastic composites
Commingle
Impregnated
Filament winding
Spray method
Sheet molding
Bulk molding
Hand lay-up
Hand lay-up
Advantages:
low cost tools
versatile: wide range of products
Disadvantages:
time consuming
easy to form air bubbles and disorientation of fibers
inconsistency
Prepreg forming
Machine
Prepreg forming
Prepreg forming
Advantages:
orientation of fibers can be changed
consistent
high productivity
Disadvantages:
continuous process needs more customers
limited shelf life
delamination
Prepreg forming
Pressure molding
Pressure molding
Advantages:
wide range of shapes
integrate parts
consistency
structural stability
relatively simple
Disadvantages:
high cost of machine
time consuming to heat up, cool down and curing
expensive molds (strong materials required)
no intricate parts
large volume of products
Vacuum bagging
Process
Vacuum bagging
Advantages:
simple design
any fiber/matrix combination
ok with cheap mold material
better quality for the cost
Disadvantages:
cannot be heated up too much
breeder clothe has to be replaced frequently
low pressure (760 mm Hg the most)
slowest speed
inconsistency
Filament winding
Filament winding
Filament winding
Filament winding
Advantages:
using existing textile processes.
quick, easy to handle package.
parts can have huge size.
Disadvantages:
spinning speed is limited due to resin penetration
and splashing, traveler speed and yarn breakage.
curing by heat is not easy to apply.
shape of the products limited (only cylindrical
possible).
Pultrusion
Pultrusion
Pultrusion
Advantages:
Automated processes.
High speed.
Versatile cross-sectional shape.
Continuous reinforcement.
Disadvantages:
Die can be easily messed up.
Expensive die.
Mainly thermoset matrix.
Spray method
Spray method
Advantages:
Continuous process
Any materials can be used as mold.
Error can be corrected by re-spraying.
Disadvantages:
Slow.
inconsistency.
No control of fiber orientation.
Only one side finished.
Environmental unfriendly.
Sheet molding
Sheet molding
Advantages
High productivity thus inexpensive
consistency
Disadvantages
low volume fraction.
Only board can be made.
Bulk molding
Bulk molding
Advantages
Highest volume fraction for short fiber reinforced
composites (50%)
Good mechanical properties
Finish can be applied
Inserts and attachments possible
Disadvantages
High temperature and high pressure
Random fiber orientation
Cannot be used for intricate parts
Staple fibers only.
http://www.plastech.co.uk/Mtrtm.html
m.htm
Disadvantages?
Filament Placement