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Composites > Composite Manufacturing > Flashcards

Composite Manufacturing Flashcards

1
Q

What are the primary processing routes for high viscosity thermoplastics?

A

injection moulding
extrusion
hot pressing

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2
Q

What are the main processing routes for low viscosity thermosets?

A

Wet lay up
pultrusion
filament winding
resin transfer moulding
pre preg lay up
compression moulding

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3
Q

why aren’t high forces used when processing low viscosity thermosets?

A

can bleed resin out of fibres
high forces can be used after solidification

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4
Q

what are the general processes used for both thermolplastic and thermosets?

A

powder processing
hot pressing
injection moulding

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5
Q

what are the general steps for manufacturing thermosets?

A
  1. Preparing the fibres and matrix
  2. combing the fibres and matrix
  3. void removal
  4. consolidation
  5. resin curing
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6
Q

how are the fibres and matrix prepared for thermosets?

A

unidirectional cloth, woven fabrics and mats cut to shape and size

mix curing agents and resin

preforms can be used for resin transfer moulding and usually made by winding/weaving/braiding

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7
Q

how are the fibres and matrix combined for thermosets?

A

wet lay up
pultrusion
filament winding
resin transfer moulding(RTM)

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8
Q

how does void removal work for thermosets?

A

must be done before cured
vacuum bagging - adds pressure removes any voids

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9
Q

how does consolidation work for thermosets?

A

pressure applied
autoclave - vacuum 1 atm

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10
Q

how does resin curing work?

A

temperature dependant on resin
higher temp generally better mechanical properties

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11
Q

How does hand lay up work?

A
  1. apply release agent to one sided mould
  2. apply gel coat
  3. place prepared fabric/mat into mould
  4. add prepared resin and work in
  5. repeat 3+4 for thickeness
  6. cure
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12
Q

What are the applications of hand lay-up?

A

lorry trailers
boats
storage tanks
baths
low performance aircraft
architectural mouldings

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13
Q

What are the advantages of hand lay-up

A

Cheap
Versatile (any goemetry)
Simple to add features(holes)
Good for prototypes
Simple mould materials (wood)

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14
Q

What are the disadvantages of hand lay-up?

A

poor properties
labour intensive
relatively slow
quality consistency
properties skill dependent
only one moulded surface
resin fumes

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15
Q

How does spray lay-up work?

A
  1. apply release agent to one sided mould
  2. apply gel coat
  3. spray chopped fibre and prepared resin into mould
  4. work in using roller (consolidation)
  5. repeat 3+4 for thickness
  6. cure
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16
Q

What are the applications for spray lay up?

A

same as hand lay up

17
Q

What are the advantages of spray lay-up?

A

Cheap
Versatile (any geometry)
simple to add holes etc
good for prototypes
simple moulds (wood)
faster than hand lay up

18
Q

What are the disadvantages of spray lay-up?

A

poorer properties than hand lay up
fibres randomly orientated and short
Labour intensive ( more automated than hand lay up)
1 moulded surface
messy, fumes

19
Q

How does pultrusion work?

A
  1. assemble reinforcements
  2. draw fibres through a resin bath (dip or drum)
  3. draw through die and cure
  4. cut to length
20
Q

What are the applications of pultrusion?

A

construction beams
piles for buildings
bridges
ladders

21
Q

What are the advantages of pultrusion?

A

any length
good surfaces
excellent fibre alignment
relatively automated once stable
quality consistency is good

22
Q

What are the disadvantages of pultrusion?

A

restricted geometry (straight constant cross section)
medium capital investment
mould materials expensive(steel)
relatively slow

23
Q

How does filament winding work?

A
  1. assemble reinforcements
  2. draw fibres through traversing resin bath
  3. wind onto mandrel
  4. braking system used to control fibre tension
  5. fibres laid side by side or overlapping
  6. cure
  7. remove from mandrel
24
Q

What are the applications of filament winding?

A

chemical storage tanks
pipelines
gas cylinders

25
Q

What are the advantages of filament winding?

A

any size
good inner surface
relatively automated
quality consistency good

26
Q

what are the disadvantages of filament winding?

A

restricted geometry (rotational symmetry)
poor outer surface
not versatile ( hard to have holes)
medium capital investment
mandrel materials expensive and limit part dimensions

27
Q

How does Resin Transfer Moulding (RTM) work?

A
  1. Place reinforcement into mould and close
  2. Pump prepared low viscosity liquid resin into mould
  3. vacuum used to draw resin through mould (optional)
  4. cure
28
Q

What are the applications of RTM?

A

small complex aircraft and automotive
train seats

29
Q

What are the advantages of RTM?

A

versatile
any size
good surfaces
relatively automated
quality consistency very good

30
Q

What are the disadvantages of RTM?

A

movement of fibres as resin injected
medium to large capital investment
high pressure so expensive mould (tool steel)
requires specific low viscosity resins

31
Q

what are 2 processes of consolidation using pre prepared materials

A

pre-preg lay-up
compression moulding of moulding compounds

32
Q

how does pre-preg lay-up work?

A
  1. cut pre-preg seets to required shape and size (automated)
  2. assemble layers into mould (autonomated)
  3. vacuum bag
  4. cure (autoclave best or hot press)
33
Q

What are the applications of pre-preg lay-up?

A

high performance aerospace
automotive
sports

34
Q

What are the advantages of pre-preg lay-up?

A

best properties available
versatile
can be automated (expensive)

35
Q

What are the disadvantages of pre-preg lay-up?

A

Very expensive
one good surface
size limited
properties are skill dependent

36
Q

how does compression moulding?

A
  1. apply weighed charge to mould in a hot press
  2. close mould and apply pressure
  3. apply heat to cure
37
Q

what are the applications of compression moulding?

A

car body panels
electrical housing

38
Q

What are the advantages of compression moulding?

A

any geometry
versatile
2 good surfaces
can be automated
good quality consistenc

39
Q

What are the disadvantages of compression moulding?

A

poor properties
versatility
medium capital investment
size limited

Composites (5 decks)

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