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Processing Thermosets Composites
Processing Thermosets Composites
Processing of Thermosets
Composites
Paolo Ermanni
9 March 2017
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 1
Contents
Introduction
Wet-Lamination Process
Flow in porous media
Resin curing kinetics
Resin viscosity
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 2
Selection criteria for manufacturing process
Selection
Economical aspects Technical aspects
Criteria
Structural features
Design and fabrication of highly
Investments integrated monolithic structures
Equipment (reduction of single parts)
Manufacturing of highly complex
Tooling shapes
Easy integration of doublers,
Labour costs inserts damping materials and
functional elements such as
Material Costs actuators and sensors.
Series volume Surface quality
Cycle time Laminate features
Safety and health Mechanical properties
Fibre architecture
aspects Fibre volume content
Quality and reproducibility
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 3
Top-level Process-chain from constituent materials to
final part
Fabrication route
Material properties
Quality features
Fibre distribution
Void content and distribution
Delamination
Fibre/matrix interface
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 4
Overview
Flow- Injection-
Draping Processes
Processes Processes
Off-line
Impregnation Prepregs
Fibre
Off-line
Rovings
Impregnation
Weben Vernähen
Flechten Wirken
Stricken Sticken
3D-Form
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 5
Contents
Introduction
Wet-Lamination Process
Flow in porous media
Resin curing kinetics
Resin viscosity
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 6
Wet Lamination technique
Preparation Forming Impregnation Curing Demolding
Resin mixing
Vacuum-bagging
Resin mixing
Vacuum-bagging
Mold
Glass fibre mats, vlies and/or fabrics
Curing usually takes place at room
temperature.
Simple molds
Post-curing at higher temperature is
possible after removal from the mold. No special requirements with
regard to temperature
Demolding resistance
Mold material: often wood or
Post-processing
resin
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 8
Wet lamination technique
Preparation Forming Impregnation Curing Demolding
Resin mixing
Vacuum-bagging
Demolding
Post-processing
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 9
Wet lamination technique
Preparation Forming Impregnation Curing Demolding
Resin mixing
Vacuum-bagging
Demolding
Post-processing
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 10
Main process features
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 11
Which of those parts would you fabricate in wet-
lamination technique?
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 12
How relevant are following criteria for the selection
of the appropriate fabrication process?
Criteria
Geometrical complexity ++ -- - - +
Tolerances + ++ = ++ +
Surface quality ++ ++ = + ++
Achievable fibre volume content -- ++ -- ++ +
Mechanical properties -- ++ - ++ +
Laminate quality = ++ -- ++ +
Reproducibility - ++ - ++ +
Investment costs ++ - ++ -- -
Labor expenses - + - -- -
Material costs ++ - ++ -- -
Number of parts p.a. -- = -- -- -
Cycle time -- + -- -- -
Criteria is not Criteria is very
relevant -- - = + ++ relevant
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 13
Typical application fields
Wind energy
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 14
Wet-lamination technique: Process variants
Schraubzwinge
Spannrahmen
Dichtung Druck
Verschraubung
gelochtes Blech
fester Deckel Druckstutzen
Rinne für überflüssiges Harz
Druckfolie
Folie
Verstärkung mit Laminat
Trennschicht
Überlauf umlaufende Dichtung
festes Werkzeugunterteil
Ventil zur Laminat
Vakuumpumpe
festes Werkzeugunterteil
Vakuumbehälter für
überflüssiges Harz
Quellen: Ehrenstein, G.W.: Faserverbund-Kunststoffe, Werkstoffe-Verarbeitung-Eigenschaften; Carl Hanser Verlag, München 1992
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 15
Process automation example
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 16
Contents
Introduction
Wet-Lamination Process
Flow in porous media
Resin curing kinetics
Resin viscosity
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 17
Flow in porous media
Darcy‘s law
Capillary number:
AK u
Q P Ca
lv cos
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 18
Flow in porous media - Background
AK
Darcy‘s law: Q P
Fluid flow is dependent on: material permeability (K), fluid viscosity (μ),
and driving pressure ( p)
Porosity is a function of compaction (required to adjust the fiber volume
fraction of the composite) of the porous media
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 19
Injection experiment in a glass tool
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 20
Darcy’s experiment
piezometric
tubes
p1
g
p2
sand g
h1
diameter D
perforated plates h2
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 21
Inside a composite: Computer Tomograph pictures
highlighting the dual-scale nature of the porous media
Schell, J.S.U., Investigation of the Influence of Meso-scale Flow Effects in Liquid Composite Moulding Processes on the Laminate Quality, Diss. ETH Nr. 17044, 2007
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 22
Dual-scale structure is influencing the impregnation
process
Mode 1 of the impregnation model
of woven fabrics
C. Lekakou, M. G. Bader, Mathematical modelling of macro- and micro- infiltration in resin transfer moulding (RTM), Composites Part A 29 (1998) 29–37.
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 23
Fiber/Matrix interface development
Fibre-wetting is a pre-condition
for developing a ‚good‘ interface!
M. Connor, Consolidation Mechanisms and Interfacial Phenomena in Thermoplastic Powder Impregnated Composites, PhD-Thesis No. 1413, EPF Lausanne, 1995
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 24
Capillary pressure
Wetting
Benetzung No wetting
Keine Benetzung
0
2 2
Capillary ascension Capillary depression
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 25
Wetting of Fibres
“Surface tension”:
dW J kg N
m2 s2 m
dA
Equilibrium condition:
2 12 1
Capillary height:
13
3
212 cos
h
gr
Capillary pressure:
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 26
Contents
Introduction
Wet-Lamination Process
Flow in porous media
Resin curing kinetics
Resin viscosity
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 27
The processing time is depending on the rheology
properties of the matrix
0,700
0,600
0,300
0,200
0,100
0,000
0 60 120 180 240 300
Zeit / s
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 28
Curing kinetics
Q dt
H ges
Kamal-Sourour model:
d
dt
k1 k 2 m 1 n
Ei
ki T Ai e RT
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 29
Contents
Introduction
Wet-Lamination Process
Flow in porous media
Resin curing kinetics
Resin viscosity
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 30
A simple viscosity model
Viscosity model:
B
C
( , T ) Ae T
ETH Zurich, Laboratory of Composite Materials and Adaptive Structures Manufacturing of Polymer Composites - Processing of Thermosets Composites | 09.03.2017 | 31