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    Fabrication Methods _ CompositesWorld

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    16 views7 pages

    Fabrication Methods - CompositesWorld

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    విష్ణువర్ధన్రెడ్డి

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    Would you like a free digital subscription? Qualified international subscribers can receive ull issues of High-Performance Composites and Composites Technolagy delivered in a convenient and interactive digital magazine format. Read at your convenience on your desktop of mobile device. Yes, | would like a free digital subscription! "No thanks, please dont ask again, Article Fabrication methods here are mae e ods for f ricatins ippsite com of Mo ae Tae were i aan ec! Pe SG ea june There are numerous methods for fabricating composite components. Some methods have been borrowed (injection ‘molding, for example), but many were developed to meet specific design or manufacturing challenges, Selection of a ‘method for a particular part, therefore, wil depend on the ‘materials, the part design and end-use or application (see "Part tesansarecangeses design criteria,” under “Editor's Picks,” at ight) Teimeraastrarms | Composite fbrtcation processes involve some form a molding. uccraemi oars ta shape the resin and reinforcement, A mols tools required to CiuiUoee otto give the unormed resin ber combination is shape prior to and amepexion¥eh® during cure. For an averview of mold types and materials and ‘fos, oa) Methods used to make mold tools. ‘Gpeeat kitesnetine, The most basi fabrication method for thermoset composites is seven fematons and tayup, wich typically consists of laying dy fabric layers, stliwarcmecnine” orples," or prepreg plies, by hand onto a tool to forma Serer laminate stack. Resin applied tothe dry ples after layup is mene complete (e.9., by means of resin infusion. In variation known as wet layup, each ply is coated with resin and “debulked or compacted air iti place. J) Several curing methods are avaliable. The most basics simply . to allow cure to occur at room temperature. Cure can be accelerated, however, by applying heat, typically with an oven, and pressure, by means of a vacuum. For the latter, a vacuum Titer ayy bag, with breather assembles, is placed over the layup and. chee Conga” attached tothe tool, then evacuated using a vacuum pump Gaming overt before cure, The vacuurn bagging process consolidates the iran plies of material and significantly reduces voids due to the off- menuacwrestasesle gassing that occurs as the matri progresses through its Retemnerahiead | Chemical ering sages ene | ary hgh perormance thermoset parts requre heat ard high SUBSCRIBE | ENEWSLETTER Fast Relable Cmpsts News LEARN MORE Editor's Picks ‘Composites repal Ber ‘Monkoring the cure Rett ‘The latest technologies measure the matrix resin's actual cure state, saving time and money. Part design rteria, Designers of composite parts can ‘choose from a wide variety of fiver reinforcements and resin sys. ‘Autoclave Quality Outside The ‘Autoclave? Pioneers of out-ofautoclave processing in aerospace applications answer a qualified but enthusiast Related Suppliers ‘Buk Molding Compounds Inc. CCytec Industal Materials HQ Zones ‘ATUAFP ‘Composites Curing Technology ‘Compression Motdlng Infusion Injection Molding Purrusion RTM -Resin Transfer Mokfing ‘Spray up ‘Supplier Categories Primary manufacturing equipment Materlals Presses ‘Aunllary processing equipment, repair equipment, and supples ‘Toolsitooting materials Vacuum bagging film with excellent flexibility Tae One Stop Tosh Shop foe Aerospace, Composite, Industri, Marine, Tooling Needs. consolidation pressure to cure — conditions that require the use of an autoclave. Autoclaves, generally, are expensive to buy and operate, Manufacturers that are equipped with autoclaves usually cure a number of parts simultaneously. Computer systems monitor and control autoclave temperature, pressure, SEE acuumand inert atmosphere, which allows unattended andlor ‘Mae orthermat. remote supervision of the cute process and maximizes efficient Groote stundinne, use ofthe technique. repeal moneys Sryeisterpcoraiesty” When heat is requited for cure, the part temperature is “ramped wennar.es up" in smal increments, maintained at cure level fora specified (Sane sity peti of ime defined by the resin system, then “ramped down’ feooaemabear-F) (6 room temperate, to avoid part distortion or warp caused by Tene aregercasaion uneven expansion and contraction, When this curing cycle is pe iewer ery complete and ater pats are demalded, some parts go through a secondary freestanding postcure, during which they are subjected for a specific period of te to a temperature higher than that ofthe intial cure to enhance chemical crosslink dens. loco beam (bear) curing has been explored as an iaameauetor |” ficient cong method fr tin laminates In e-beam curing, the memwsAmmcm Compost ays exposed 10a steam of elecvons that Machine Toots Rackterd, .), provide ionizing radiation, causing polymerization and Ne era ence, | ucaithingin ati sotive teats Kay aed microwave Ciipopsasemewe’_curng technologies work na similar manner. fourth tuetsnstra‘e sever iterative, ultaviotet (UV) curing, involves the use of UV overseas pverger__ radiation to activate a photoinitiator added to a thermoset resin, Kee krsinmachdewet hich, when actvated, sets off a crosslinking reaction. UV (Minewerantreveny” Curing requires ight-permeable resin and reinforcements. (praia Set, are Soainaecerae An emerging technology isthe monitoring of the cure iset = iclectrc cure monitors measure the extent of cure by gauging the conduetivty of ions — small, polarized, relaively insignificant impurities that are resident in resins. ons tend to migrate toward an electrode of opposite polarity, but the ‘speed of migration is limited by the viscosity of the resin — the higher the viscosity, the slower the speed. As crosslinking proceeds during cute, resin viscosity increases. Other methods include dipole monitoring within the resin, tie monitoring of microvoltage produced by the crossiinking, monitoring of the exothermic reaction in the polymer during cure and, potentially, the use of infrared monitoring via fiber-optic technology (see ‘Monitoring the cure ise," under "Eaito’s Picks,” at right). ‘A notable phenomenon gaining momentum in the industry is that of outof-autoclave (©0A) curing for high-performance composite components. The high cost and limited size ‘of autociave systems has prompted many processors, particularly in aerospace, to call for ‘O04 resins that can be cured with heat only in an oven (less capital-intensive and less ‘expensive to operate than an autoclave, particularly with very large parts), or at room temperature, Cytec Industrial Materials (fonmetly Advanced Composites Group, Heanor, Derbyshire, U.K,) introduced the frst OOA resin, an epoxy designed for aerospace applications. OOA tooling epoxies and adhesives also are coming to market (see “Autoclave quality outsiae the autoclave under “Editor's Picks’). ‘Open moiding ‘Open contact molding in one-sided molds isa low-cost, common process for making fiberglass composite products. Typically used for boat hulls and decks, RV components, ‘tuck cabs and fenders, spas, vathtubs, shower stalls and other relatively large, noncomplex shapes, open malding involves eitner hand layup o° a semi-automated alternative, sprayup. Inn open-mold sprayup application, the mold is frst veated with mold release. it gel coat is used, tis typically sprayed into the mold after the mold release has been applied ‘The gel coal then is cured and the mol is ready for fabrication to begin. In the sprayup process, catalyzed resin (viscosity trom 500 to 1,000 cps) and glass fiber are sprayed into the mold using a chopper gun, which chops continuous fier into short lengths, then blows. the shor fibers directly into the sprayed resin stream so that both materials are applied simutaneously. To reduce VOCS, piston pump-activated, non-atomizing spray guns and {luid impingement spray heads dispense gel coats and resins in larger droplets at low pressure. Another option is a roller impregnator, which pumps resin into a roller similar to a paint roller In the final steps of the sprayup process, workers compact the laminate by hand with rollers, Wood, foam or other core material may then be added, and a second sprayup layer imbeds the core between the laminate skins. The partis then cured, cooled and removed from the reusable mald Hand layup and sprayup methods are often used in tandem to reduce labor. For example, ot y REGISTER TODAY & SAVE DECEMBER 8-10, 2015 bo e-To |) Ciceaad fabric might fist be placed in an area exposed to high stress; then, a spray gun might be used to apply chopped glass and resin to build up the rest ofthe laminate. Balsa or foam cores may be inserted between the laminate layers in etther process. Typical glass fiber volume is 15 percent with sprayup and 25 percent with hand layup. Sprayup processing, once a vely prevalent manufacturing method, has begun to fall out of favor. Federal regulations in the U.S. and similar rules in the EU have mandated limits on worker exposure to, and emission into the environment of VOCs and hazardous air pollutants (HAPS), Styrene, the most common monomer used as a diluent in thermoset resins, is on both lists. Because worker exposure (o and emission of styrene is dificult and ‘expensive to conirol in the sprayup process, many composites manufacturers have migrated to closed mold, infusion-based processes, which better contain and manage styrenes, ‘Although open molding via hand layup is being replaced by faster and more technically precise methods (as the following makes clear) itis sill widely used inthe repair of ‘composite parts. For more information about "Composites repair” see the so-named article under "Editor's Picks.” Resh Infusion processes Ever increasing demand for faster production rates has pressed the industry to replace hand layup with alternative fabrication processes and has encouraged fabricators to automate those processes wherever possible. ‘A.common alternative is resin transfer molding (RTM), sometimes refered to as liquid molding. RTM is a farly simple process: It begins with a two-part, matched, closed mold that is made of metal or composite material. Dry reinforcement (typically a preform) is placed into the mold and the mold is closea. Resin and catalyst are metered and mixed in dispensing equipment, then pumped into the mold under low to moderate pressure through injection ports, following predesigned paths through the preform. Extremely Iow- viscosity resin is used in RTM applications for thick parts to permeate preforms quickly and evenly before cure, Both mold and resin can be heated, as necessary, for particular applications. RTM produces parts without an autoclave. However, when cured and

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