mse_mantech_composite process fundamentals
Manufacturing Technologies MSEcomposite process fundamentals
Manufacturing Technologies MSEcomposite process fundamentals
Description of Hand Lamination / Wet Lamination
Hand Lamination Process Sequence
1D: Fibre Roving
2D: Fleece Fabric NCF
cut: Cut (flatwrap)
form: drape
3D: preform
wet: impregnate
cure: component
Description Fibre Spraying
Fibre Spraying Process Sequence
1D: fibre roving
cut: chopping
wet: impregnate
form: spraying
2D + 3D: compacting
cure: component
Description Prepreg Autoclave
Prepreg Autoclave Equipement Technology
Prepreg Autoclave Overview and Distinction
Prepreg autoclave materials
- Thermoset prepregs, which consolidate under temperature and pressure and chemically cross-link
- Thermoplastic prepregs which are consolidated by meldting the matrix under pressure
- film stacking strauctures in which a dry tectile fibre semi-finished product and thermolastic film are alternately applied. impregnation and consolidation are also carried out under pressure temperature
- textile semi-finished products made of hybrid yarns in which a part of the yard melts and takes over the function of the matrix (e.g. GF/PP)
- fibre structures in which the thermoplastic matrix is added manually as powder or granulate between the individual layers
Prepreg Thermoset / Thermoplastic
Since thermoplastic prepregs cannot be sheared at room temperature, they can almost exclusively be used for unwrappable surfaces
Autoclave layup sequence
Autoclave auxiliary materials
- vacuum foil
- suction tissue
- seal between tool and vacuum foil
- peel-off fabric (peel-ply)
- separatig foil / perforated foil
Prepreg Autoclave Process Sequence
1D: fibre roving
2D: Fabric NCF
wet: prepreg manufacture (immersion bath)
cut: cutting by hand / NC cutter
preform: form
3D: compaction
cure: autoclave part
Prepreg Autoclave Process Parameters
- The pressure in the autoclave should always be kept as high as possible in order to achieve good consolidation
- in the case of thermoplastics, the vacuum is decisive to avoid a reaction (oxidation = degradation) of the matrix with the redicual oxygen
- in case of thermosets, the vacuum must not be reduced too much in order to avoid outgassing of volatile substances
Prepreg Autoclave Temperature, Pressure and Vacuum
Comparison Wet Laminate to Prepregs
Resin Transfer Moulding (RTM) steps
- cleaning of the mould (removal of resing reidues), drilling out sprue and vacuum channel
- checking the seals
- application of release agents in the tool
- inserting the preform and other function elements (e.g. inserts)
- closing the tool
- create vacuum. Evacuation of residual air in the cavity
- injection of the reactive resin (1K or 2K) through a pressure vessel or volume pump
- after complete filling: disconnect vacuum
- press the resin until gelation is achieved
- curing component in closed mould
- opmeing the mould and demoulding
- if necessary tempering
- finishing
darc'y law
Injection Process
1D: fibre roving
2D: fabric ncf fleece
cut: cut
form: drape
3D: preform
wet: infusion injection
cure: part
Vaxuum infuction (VI) RTM Light - Short Description
One tool hald shell with membrane
Vacuum assisted resin infusion (VARI) - Short Description
A rigid tool half combined with a semi-rigid shell
(Vacuum assisted) resin transfer moulding (RTM, VARTM)
High Pressure RTM (HPRTM); Structural raction injection moulding (SRIM)
- Short Description
Two rigid half-shells, i.e. good surface quality on both sides, injection with pressure
advanced RTM (ARTM)
IKV gap impregnation
Compression RTM
- Short Description
Combined RTM and pressing process with two rigid tool half shells with the aim of reducing impregnation time
thermal expansion RTM (TERM) - Short Description
Expansion of the core during consolidation
Differential Pressure RTM
Autoclave RTM
Resin Transfer Infusion (RTI)
Special case of tube blowing RTM
- Short Description
One tool half shell with membrane, curing under pressure and temperature in autoclave if necessary
Thermoplast RTM (TPRTM) - Short Description
RTM with thermoplastic resin system
Vacuum Infusion (VI), RTM Light
Vacuum Assisted Resin Infustion (VARI)
Resin Transfer Moulding (RTM)
Winding Technology
Production of rotationally symetrical bodies
Typical components:
pupes
masts
pressure tanks
silos
cardan shafts
Winding Proecess Basics
Radial Winding process
Cross winding method
Polar winding method
Pressing Technologies
Pressing Processing Steps
1D: fibre roving
2D: Fleece
wet: Impregnation
cut: cut
form & 3D: impact extrusion
cure: cooling
GMT/LFT Processing Technology
Sheet Moulding Compound (SMC impact extrusion)
Pultrusion
- Impregnation
- Shaping
- Curing / Cooling
Process Variants:
Thermoset: Impregnation of the reinforcing materials in a resin bath followed by curing in a shaping tool
Thermoplastic: Use of prepregs, which are melted in a continous furnace and then moulded and cooled in a tool
Pultrusion - Processing Steps
1D: fibre roving
2D: fleece fabric NCF
wet: wetting in resin bath
form & 3D: forming in die/nozzle
cure: cross-linking
cut: saw
Composite materials
standard:
fibre reinforcements:
- glass fibres: high strength, medium stiffness, low cost
- carbon: very high strength and stiffnes, high costs
matrices:
- usually thermoset resins -> low visocity allows impregnaton of single gibres within the fiber bundles
- polyester due to cost reasons
- epoxy due to mechanical and chemical properties
Renewable resources:
fibres:
- flax: mechanical properties comparable to glass, excellent damping properties
matrices:
- tannin-furfuryl (like corn or bran)
Tannin based systems compatibility proceses
- Hand layup
- Resin infusion
- RTM
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Lernkarten
Description of Hand Lamination / Wet Lamination
Hand Lamination Process Sequence
1D: Fibre Roving
2D: Fleece Fabric NCF
cut: Cut (flatwrap)
form: drape
3D: preform
wet: impregnate
cure: component
Description Fibre Spraying
Fibre Spraying Process Sequence
1D: fibre roving
cut: chopping
wet: impregnate
form: spraying
2D + 3D: compacting
cure: component
Description Prepreg Autoclave
Prepreg Autoclave Equipement Technology
Prepreg Autoclave Overview and Distinction
Prepreg autoclave materials
- Thermoset prepregs, which consolidate under temperature and pressure and chemically cross-link
- Thermoplastic prepregs which are consolidated by meldting the matrix under pressure
- film stacking strauctures in which a dry tectile fibre semi-finished product and thermolastic film are alternately applied. impregnation and consolidation are also carried out under pressure temperature
- textile semi-finished products made of hybrid yarns in which a part of the yard melts and takes over the function of the matrix (e.g. GF/PP)
- fibre structures in which the thermoplastic matrix is added manually as powder or granulate between the individual layers
Prepreg Thermoset / Thermoplastic
Since thermoplastic prepregs cannot be sheared at room temperature, they can almost exclusively be used for unwrappable surfaces
Autoclave layup sequence
Autoclave auxiliary materials
- vacuum foil
- suction tissue
- seal between tool and vacuum foil
- peel-off fabric (peel-ply)
- separatig foil / perforated foil
Prepreg Autoclave Process Sequence
1D: fibre roving
2D: Fabric NCF
wet: prepreg manufacture (immersion bath)
cut: cutting by hand / NC cutter
preform: form
3D: compaction
cure: autoclave part
Prepreg Autoclave Process Parameters
- The pressure in the autoclave should always be kept as high as possible in order to achieve good consolidation
- in the case of thermoplastics, the vacuum is decisive to avoid a reaction (oxidation = degradation) of the matrix with the redicual oxygen
- in case of thermosets, the vacuum must not be reduced too much in order to avoid outgassing of volatile substances
Prepreg Autoclave Temperature, Pressure and Vacuum
Comparison Wet Laminate to Prepregs
Resin Transfer Moulding (RTM) steps
- cleaning of the mould (removal of resing reidues), drilling out sprue and vacuum channel
- checking the seals
- application of release agents in the tool
- inserting the preform and other function elements (e.g. inserts)
- closing the tool
- create vacuum. Evacuation of residual air in the cavity
- injection of the reactive resin (1K or 2K) through a pressure vessel or volume pump
- after complete filling: disconnect vacuum
- press the resin until gelation is achieved
- curing component in closed mould
- opmeing the mould and demoulding
- if necessary tempering
- finishing
darc'y law
Injection Process
1D: fibre roving
2D: fabric ncf fleece
cut: cut
form: drape
3D: preform
wet: infusion injection
cure: part
Vaxuum infuction (VI) RTM Light - Short Description
One tool hald shell with membrane
Vacuum assisted resin infusion (VARI) - Short Description
A rigid tool half combined with a semi-rigid shell
(Vacuum assisted) resin transfer moulding (RTM, VARTM)
High Pressure RTM (HPRTM); Structural raction injection moulding (SRIM)
- Short Description
Two rigid half-shells, i.e. good surface quality on both sides, injection with pressure
advanced RTM (ARTM)
IKV gap impregnation
Compression RTM
- Short Description
Combined RTM and pressing process with two rigid tool half shells with the aim of reducing impregnation time
thermal expansion RTM (TERM) - Short Description
Expansion of the core during consolidation
Differential Pressure RTM
Autoclave RTM
Resin Transfer Infusion (RTI)
Special case of tube blowing RTM
- Short Description
One tool half shell with membrane, curing under pressure and temperature in autoclave if necessary
Thermoplast RTM (TPRTM) - Short Description
RTM with thermoplastic resin system
Vacuum Infusion (VI), RTM Light
Vacuum Assisted Resin Infustion (VARI)
Resin Transfer Moulding (RTM)
Winding Technology
Production of rotationally symetrical bodies
Typical components:
pupes
masts
pressure tanks
silos
cardan shafts
Winding Proecess Basics
Radial Winding process
Cross winding method
Polar winding method
Pressing Technologies
Pressing Processing Steps
1D: fibre roving
2D: Fleece
wet: Impregnation
cut: cut
form & 3D: impact extrusion
cure: cooling
GMT/LFT Processing Technology
Sheet Moulding Compound (SMC impact extrusion)
Pultrusion
- Impregnation
- Shaping
- Curing / Cooling
Process Variants:
Thermoset: Impregnation of the reinforcing materials in a resin bath followed by curing in a shaping tool
Thermoplastic: Use of prepregs, which are melted in a continous furnace and then moulded and cooled in a tool
Pultrusion - Processing Steps
1D: fibre roving
2D: fleece fabric NCF
wet: wetting in resin bath
form & 3D: forming in die/nozzle
cure: cross-linking
cut: saw
Composite materials
standard:
fibre reinforcements:
- glass fibres: high strength, medium stiffness, low cost
- carbon: very high strength and stiffnes, high costs
matrices:
- usually thermoset resins -> low visocity allows impregnaton of single gibres within the fiber bundles
- polyester due to cost reasons
- epoxy due to mechanical and chemical properties
Renewable resources:
fibres:
- flax: mechanical properties comparable to glass, excellent damping properties
matrices:
- tannin-furfuryl (like corn or bran)
Tannin based systems compatibility proceses
- Hand layup
- Resin infusion
- RTM
