Copyrighted Materials Copyright009 DEStech Publications Retrieved from www.knovel.com PART 1 Fundamentals of Constituents for Composites Manufacturing
PART 1 Fundamentals of Constituents for Composites Manufacturing
CHAPTER 1 Introduction Advanced composite materials have been used to fabricate many structural parts in engineering applications. This is due to their many at- tractive characteristics such as light weight, high strength, high stiffness, good fatigue resistance and good corrosion resistance. Also, the ability to manufacture parts with complicated geometry using fewer compo- nents enables manufacturers to save cost as compared with the same parts made of conventional metallic materials. Before presenting the fun- damental aspects of manufacturing and different techniques used for composites manufacturing, it is appropriate to present composite struc- tural parts currently in use and the main techniques that have been used to fabricate them. 1. EXAMPLES OF PRODUCTS MADE USING DIFFERENT MANUFACTURING TECHNIQUES Figure 1.1(a) shows a schematic of an Airbus 380 airplane(the largest airplane in the world as of 2008). This airplane has more than 50% of its structure made of composite materials. These components include the flaps, ailerons, rudder, radome etc. Most of these components are flat in shape and they are usually made using hand-lay-up (HLU) and autoclave molding techniques. Figure 1.1(b) shows a schematic of the hand-lay-up fabrication technique and a representative lay-up sequence. Autoclave molding is a well-established method for composites used in the aero- space industry with certified resins and fibers. A photograph of an auto- clave is shown in Figure 1.1(c). Autoclave Molding will be discussed in detail in Chapter 4. 3
CHAPTER 1 Advanced composite materials have been used to fabricate many structural parts in engineering applications. This is due to their many attractive characteristics such as light weight, high strength, high stiffness, good fatigue resistance and good corrosion resistance. Also, the ability to manufacture parts with complicated geometry using fewer components enables manufacturers to save cost as compared with the same parts made of conventional metallic materials. Before presenting the fundamental aspects of manufacturing and different techniques used for composites manufacturing, it is appropriate to present composite structural parts currently in use and the main techniques that have been used to fabricate them. 1. EXAMPLES OF PRODUCTS MADE USING DIFFERENT MANUFACTURING TECHNIQUES Figure 1.1(a) shows a schematic of an Airbus 380 airplane (the largest airplane in the world as of 2008). This airplane has more than 50% of its structure made of composite materials. These components include the flaps, ailerons, rudder, radome etc. Most of these components are flat in shape and they are usually made using hand-lay-up (HLU) and autoclave molding techniques. Figure 1.1(b) shows a schematic of the hand-lay-up fabrication technique and a representative lay-up sequence. Autoclave molding is a well-established method for composites used in the aerospace industry with certified resins and fibers. A photograph of an autoclave is shown in Figure 1.1(c). Autoclave Molding will be discussed in detail in Chapter 4. 3
■CFRP Vertcal stabilger- ▣GFRP Leading edge J-nose Tal ☐Hybnd (G+C 一Flap tra fainngs cone ☐GLARE Pes复Je Apron Upper-deck floor beams Bely fainng skins Overwing pane 一Trailing edo3 Radome and5 hroud bo线 一Spoiers Main and centre. landing gear doors Nose landing Main landing gear doors 9e3w9 fairing door Central Torsion Box Pylon fairngs and nacelles cowings FIGURE 1.1(a)Airbus 380 with its composite component (from http://www. specialchem4adhesives.com/home/editorial.aspx?id=752). 8 90 0 FIGURE 1.I(b)Schematic of the hand-lay-up fabrication method and a representative lay-up sequence.Individual layers can be cut by hand or by a computerized machine cut- ter.The layers can be stacked one on top of the other by hand or by a robot. 4
FIGURE 1.1(a) Airbus 380 with its composite component (from http://www. specialchem4adhesives.com/home/editorial.aspx?id=752). FIGURE 1.1(b) Schematic of the hand-lay-up fabrication method and a representative lay-up sequence. Individual layers can be cut by hand or by a computerized machine cutter. The layers can be stacked one on top of the other by hand or by a robot. 4
Examples of Products Made Using Different Manufacturing Techniques 5 FIGURE I.I(c)Photograph of an autoclave (courtesy of ASC Ltd.). Figure 1.2(a)shows a pressure vessel made of composite materials us- ing the combination of hand-lay-up and filament winding processes. Composite pressure vessels are light weight and can contain pressures higher than those contained by metallic vessels.These components are made using the filament winding process [Figure 1.2(b)].Figure 1.2(c) shows a photograph of a filament winding machine.The filament wind- ing process will be discussed in detail in Chapter 5. FIGURE 1.2(a)Composite pressure vessel made by combination of hand-lay-up and filament winding
Figure 1.2(a) shows a pressure vessel made of composite materials using the combination of hand-lay-up and filament winding processes. Composite pressure vessels are light weight and can contain pressures higher than those contained by metallic vessels. These components are made using the filament winding process [Figure 1.2(b)]. Figure 1.2(c) shows a photograph of a filament winding machine. The filament winding process will be discussed in detail in Chapter 5. Examples of Products Made Using Different Manufacturing Techniques 5 FIGURE 1.1(c) Photograph of an autoclave (courtesy of ASC Ltd.). FIGURE 1.2(a) Composite pressure vessel made by combination of hand-lay-up and filament winding
FIGURE 1.2(b)Schematic of the filament winding process (courtesy of Wiley Interscience). FIGURE 1.2(c)A two-spindle winder with a carriage-mounted resin bath and a free- standing creel in the background (courtesy of Composites Technology magazine,August 2005). 6
FIGURE 1.2(b) Schematic of the filament winding process (courtesy of Wiley Interscience). FIGURE 1.2(c) A two-spindle winder with a carriage-mounted resin bath and a freestanding creel in the background (courtesy of Composites Technology magazine, August 2005). 6
Examples of Products Made Using Different Manufacturing Techniques 7 FIGURE 1.3(a)A composite pultruded connector. Figure 1.3(a)shows a component made using pultrusion.Pultrusion is used to make many structures for civil engineering applications.Figure 1.3(b)shows the schematic of the pultrusion process,and Figure 1.3(c) shows a photograph of a lab scale pultrusion machine.Pultrusion will be discussed in Chapter 6. Figure 1.4(a)shows a composite component made using the liquid composite molding (LCM)method(5 piece).LCM has been used to make automobile composite components.Figure 1.4(b)shows a sche- matic of the liquid composite molding process and Figure 1.4(c)shows a pump,a mold and accessories for the liquid composite molding hard- ware.Liquid composite molding will be discussed in Chapter 7. ROVING RESIN BATH CONTINUOUS MAT PULLER MANDREL -PREFORMING DIES- RESIN BATH HEATED DIE CONTINUOUS MAT FIGURE 1.3(b)Schematic of the pultrusion process(courtesy of Springer)
Figure 1.3(a) shows a component made using pultrusion. Pultrusion is used to make many structures for civil engineering applications. Figure 1.3(b) shows the schematic of the pultrusion process, and Figure 1.3(c) shows a photograph of a lab scale pultrusion machine. Pultrusion will be discussed in Chapter 6. Figure 1.4(a) shows a composite component made using the liquid composite molding (LCM) method (5 piece). LCM has been used to make automobile composite components. Figure 1.4(b) shows a schematic of the liquid composite molding process and Figure 1.4(c) shows a pump, a mold and accessories for the liquid composite molding hardware. Liquid composite molding will be discussed in Chapter 7. Examples of Products Made Using Different Manufacturing Techniques 7 FIGURE 1.3(a) A composite pultruded connector. FIGURE 1.3(b) Schematic of the pultrusion process (courtesy of Springer)
Pultrusion FIGURE 1.3(c)A lab pultrusion machine. FIGURE 1.4(a)A curved piece made by Liquid Composite Molding (LCM)method. 8
8 FIGURE 1.3(c) A lab pultrusion machine. FIGURE 1.4(a) A curved piece made by Liquid Composite Molding (LCM) method
Injection Tool Ratio Control De-mold Cure Preform Resin FIGURE 1.4(b)Schematic of the liquid composite molding process. BE CAREFUL RTM Injector FIGURE 1.4(c)Instrumentation for LCM:pump,mold and accessories.Resin is filled into the vertical cylinder,then pumped into the mold cavity on the left-hand side. 9
9 FIGURE 1.4(b) Schematic of the liquid composite molding process. FIGURE 1.4(c) Instrumentation for LCM: pump, mold and accessories. Resin is filled into the vertical cylinder, then pumped into the mold cavity on the left-hand side
10 INTRODUCTION FIGURE 1.5(a)A thermoplastic composite wing box panel made by compression molding. Figure 1.5(a)shows a composite wing box panel made using thermo- plastic composites and compression molding method.Figure 1.5(b) shows the schematic for the thermoplastic composite molding process. Figure 1.5(c)shows a compression molding machine.Molding of ther- moplastic composites will be discussed in Chapter 8. Compression molding Female cavity Male mold Male mold on the bottom Female mold on the bottom FIGURE 1.5(b)Schematic of the thermoplastic composite molding process
Figure 1.5(a) shows a composite wing box panel made using thermoplastic composites and compression molding method. Figure 1.5(b) shows the schematic for the thermoplastic composite molding process. Figure 1.5(c) shows a compression molding machine. Molding of thermoplastic composites will be discussed in Chapter 8. 10 INTRODUCTION FIGURE 1.5(a) A thermoplastic composite wing box panel made by compression molding. FIGURE 1.5(b) Schematic of the thermoplastic composite molding process
Examples of Products Made Using Different Manufacturing Techniques 11 FIGURE 1.5(c)A compression molding machine. Figure 1.6(a)shows a thermoplastic composite tube made by the fiber placement process.Figure 1.6(b)shows the schematic of the thermoplas- tic composite placement process,and Figure 1.6(c)shows a photograph of a fiber placement machine.Fiber placement of thermoplastic compos- ites will be discussed in Chapter 8. FIGURE 1.6(a)A thermoplastic composite tube made by the fiber placement process
Figure 1.6(a) shows a thermoplastic composite tube made by the fiber placement process. Figure 1.6(b) shows the schematic of the thermoplastic composite placement process, and Figure 1.6(c) shows a photograph of a fiber placement machine. Fiber placement of thermoplastic composites will be discussed in Chapter 8. Examples of Products Made Using Different Manufacturing Techniques 11 FIGURE 1.5(c) A compression molding machine. FIGURE 1.6(a) A thermoplastic composite tube made by the fiber placement process