Composites 1

Composites Processing
ver. 1
ME 4210: Manufacturing Processes and

Engineering Prof. J.S. Colton GIT 2011
Definition
A microscopic mixture of two or more
different materials. One typically being
the continuous phase (matrix), and the
other being the discontinuous phase
(reinforcement).
Its properties are strongly dependent on
the composite structure.
Ductility of matrix combined with
stiffness of reinforcement.
Ceramic fiber composite
Polymer matrix composite

Types / Examples
People
Trees
Fiber reinforced matrices
fiberglass - epoxy
Particulate reinforced matrices

tires (carbon black in rubber, but it also has
continuous fibers (steel or polymer belts))

Fibers/Particles Reinforcement
Glass
Kevlar
Carbon
Thermoplastics
Alumina
Boron
SiC
Steel
Si3N4
Silica
Glass beads
Talc
Rocks
Carbon black
Calcium carbonate

Reinforcements
Rovings
continuous
bulk
Continuous strand mat

Chopped strand mat
Surface veils
Matrices
Protects & separates reinforcement, transmits
forces
Polymer
PEEK, epoxy, polyester, polyurethane, rubber
Metal
Al, Cu, Ni, Ti
Ceramic
glass, cement

Honeycomb composites

C-17 Aircraft

Visby Corvette

10
Razzle Dazzle Camouflage

11
Stealth Ships

12
IsoTruss Bike

13
Processes
Hand lay-up
Vacuum bagging/autoclave
Compression molding
SMC/BMC
Liquid resin molding

Resin transfer molding

14
Processes
Pultrusion
Filament winding
Injection molding
Thermoplastics processing
Automated tape laying

15
Manual lay-up
Definition: A process
wherein the application of
resin and reinforcement is
done by hand onto a suitable
mold surface. The resulting
laminate is allowed to cure in
place without further
treatment

16
Hand spray-up

17
Hand lay-up shop

18
Molds

19
Mold

20
Vacuum bag assembly

21
Vacuum bag
Breather
Bleeder

22
Lay-up
Material on stiffening
structure
Vacuum bag and

fittings attached
23
Autoclave

24
Autoclave

25
Delta II Rocket

26
Delta II rocket

27
Can be used with bulk molding compound (BMC)

28

29
Schematic of a compression molding press

30
Car parts with Sheet Molding

Compound (SMC) - Prowler

31
SMC manufacture using a configuration that can make chopped-fiber

SMC-R; continuous fiber SMC-C; or continuous, random SMC-C/R
material

32
Molding process

33
Fiber orientation

34
Resin transfer molding (RTM) process

35
RTM applications
Auto body panels
Truck air
deflectors
Wind blades
Chemical storage
tanks
Solar collectors
(40 ft diameter,
36 parts)
RV components
Propellers
Bathtub/shower
units
Antenna dishes
Chairs
Swim pool panels

36
Car parts

37
RTM automobile structure

38
Truck

39
Train Compartment

40
Train Compartment

41
Plenum method for making preforms

42
Schematic of high-speed RTM process

43

44
SCRIMP Boat Hulls

45
Pultrusion process

46
Fiber let-off
Preforming
Curing die
Cut-off saw
Fiber guides

Resin impregnation
47
Puller
Reinforcements
Rovings
continuous
bulk
Continuous strand mat

Chopped strand mat
Surface veils
48
Continuous fiber reinforcement pultusion

49
Hollow structure pultrusion process

50
RIM (Reaction Injection Molding) pultrusion

51
Exploded view of pultruded composite

52
Bank of America Building Spire

53
Pultruded bridges

54
Pultruded
I-beam

55
Filament winding

56
GTs machine

57
Filament winding machines

58
Delta IV Rocket faring

mandrel

59
Reusable Mandrels
Figure 1: A Veriflex cylinder is fabricated.
Figure 2: The cylinder is placed in a clamshell mold,

heated, and blow-molded into a complex-shaped mandrel.
60
Reusable Mandrels
Figure 3: The mandrel is cooled below the transition

temperature resulting in a rigid mandrel.
Figure 4: The mandrel is filament-wound and then cured.

The cure process for the composite does not affect the mandrel.
61
Reusable Mandrels
Figure 5: After the composite is cured, the Veriflex mandrel is heated

above its activation temperature. The Veriflex then becomes pliable and
is removed. The transition temperature does not affect the composite.
Figure 6: The complex part is completed. The cylindrical

Veriflex mandrel, which returned to its "memory" shape
while above its transition temperature, can be reused.
62
Creel tensioners

63
Integral head resin wet-out bath

64
Winding pins for low angle winding

65
Continuous curing oven

66
Layout of a computer-controlled
filament-winding machine

67
Gas tanks

68
Aerospace parts
F-16
Patriot missile
Soviet missile

69
Rocket Motor Casings

70
Tape laying 787 fuselage

71
Tape laying 787 fuselage

72
Composite motors

73
Sporting goods

74
Glass epoxy filament-wound 9-foot-diameter by 55-footlong assembled railway tank car

75
Pipe machine and cure oven

76
Light pole

77
Thermoplastics processing

78
Injection molding
Clamp
Mold
Barrel
Hopper

79
Injection molding
pellets
clamp
nozzle
hopper
barrel
throat
mold
cavity
screw
heaters

motor /
drive
80
Roll forming

81
Roll-formed part

82
Matched die forming

adjustment bolts
sample and
holder
alignment pins
weights

83
Press forming of LDF

(long discontinuous fibers)
Heat material
Transfer into
heated dies
Clamp and
thermoform

Formed component
after trimming
84
Compression molding

85
Compression molding sequence

86
Hydroforming

87
Diaphragm forming

88
Diaphragm forming

89
Vacuum forming in autoclave

90
Stretch forming

91
Tape laying

92

93
Automated Tow Placement

- Thermoplastics

94
Robotic thermoplastic ATP machine
NASA Langley
95
Filament winding thermoplastic ATP

machines

96
Filament winding thermoset ATP

machine

97
Large ATP machine

98
Typical parts

99

100

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Composites Processing

ME 4210: Manufacturing Processes and

Ceramic fiber composite

Polymer matrix composite

Particulate reinforced matrices

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

Continuous strand mat

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

Razzle Dazzle Camouflage

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

Liquid resin molding

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

Hand lay-up shop

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

Vacuum bag assembly

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

Vacuum bag and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

Can be used with bulk molding compound (BMC)

ME 4210: Manufacturing Processes and

Schematic of a compression molding press

ME 4210: Manufacturing Processes and

Car parts with Sheet Molding

ME 4210: Manufacturing Processes and

SMC manufacture using a configuration that can make chopped-fiber

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

Resin transfer molding (RTM) process

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

RTM automobile structure

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

Plenum method for making preforms

ME 4210: Manufacturing Processes and

Schematic of high-speed RTM process

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

SCRIMP Boat Hulls

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

ME 4210: Manufacturing Processes and

Continuous strand mat

Continuous fiber reinforcement pultusion

ME 4210: Manufacturing Processes and