Composites Processing
This document was uploaded by user and they confirmed that they have the permission to share it. If you are author or own the copyright of this book, please report to us by using this DMCA report form. Report DMCA
Overview
Download & View Composites Processing as PDF for free.
More details
- Words: 2,104
- Pages: 97
Composites Processing ver. 1
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
1
Definition • A microscopic mixture of two or more different materials. materials One typically being the continuous phase (matrix), and the other being the discontinuous phase (reinforcement). • Its It properties ti are strongly t l dependent d d t on the composite structure. • Ductility of matrix combined with stiffness of reinforcement. ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
2
Ceramic fiber composite Polymer matrix composite ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
3
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))
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
4
Fibers/Particles Reinforcement • • • • • • • • •
Glass Kevlar Carbon Thermoplastics Alumina Boron SiC Steel Si3N4
• • • • • •
Silica Glass beads Talc Rocks Carbon black Calcium carbonate
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
5
Reinforcements
• Rovings – continuous – bulk
• Continuous strand mat • Chopped strand mat • Surface veils ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
6
Matrices • Protects & separates reinforcement, transmits forces • Polymer – PEEK, PEEK epoxy, polyester, l polyurethane, l h rubber bb
• Metal – Al, Al C Cu, Ni Ni, Ti
• Ceramic – glass, glass cement
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
7
Honeycomb composites
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
8
C 17 Aircraft C-17
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
9
Visby Corvette
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
10
IsoTruss Bike
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
11
Processes • Hand lay-up • Vacuum V b bagging/autoclave i / l • Compression molding – SMC/BMC
• Liquid resin molding • Resin transfer molding
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
12
Processes • • • • •
Pultrusion Filament winding Injection molding Th Thermoplastics l ti processing i Automated tape laying
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
13
Manual lay lay-up 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
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
14
Hand spray spray-up up
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
15
Hand lay lay-up up shop
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
16
Molds
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
17
Mold
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
18
Vacuum bag assembly
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
19
Vacuum bag Breather Bleeder
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
20
Lay-up y p Material i l on stiffening iff i structure
Vacuum bag and fittings attached ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
21
Autoclave
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
22
Autoclave
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
23
Delta II Rocket
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
24
Delta II rocket
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
25
Can be used with bulk molding g compound p ((BMC)) ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
26
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
27
Schematic of a compression molding press
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
28
Car parts with Sheet Molding Compound (SMC) - Prowler
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
29
SMC manufacture using a configuration that can make chopped-fiber SMC-R; continuous fiber SMC-C; or continuous, random SMC-C/R material
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
30
Molding process
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
31
Fiber orientation
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
32
Resin transfer molding (RTM) process
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
33
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
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
34
Car parts
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
35
RTM automobile t bil structure t t
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
36
Truck
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
37
Train Compartment
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
38
Train Compartment p
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
39
Plenum method for making preforms
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
40
Schematic of high-speed RTM process
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
41
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
42
SCRIMP – Boat Hulls
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
43
Pultrusion process p
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
44
Fiber let-off let off
Preforming
Curing die
Cut-off saw
Fiber guides
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
Resin impregnation
45
Puller
Reinforcements
• Rovings – continuous – bulk
• Continuous strand mat • Chopped strand mat • Surface veils ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
46
Continuous fiber reinforcement pultusion
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
47
Hollow structure pultrusion process
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
48
RIM (Reaction Injection Molding) pultrusion
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
49
Exploded view of pultruded composite
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
50
Bank of America Building Spire
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
51
Pultruded bridges g
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
52
Pultruded I-beam
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
53
Filament winding g
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
54
GT’s machine
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
55
Filament winding g machines
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
56
Delta IV Rocket faring g mandrel
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
57
Reusable Mandrels
Figure gu e 1: A Veriflex™ e e cy cylinder de is s fabricated. ab cated
Figure 2: The cylinder is placed in a clamshell mold mold, heated, and blow-molded into a complex-shaped mandrel. ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
58
Reusable Mandrels
Figure 3: The mandrel is cooled below the transition temperature resulting in a rigid mandrel.
Figure 4: The mandrel is filament-wound filament wound and then cured cured. The cure process for the composite does not affect the mandrel. ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
59
Reusable Mandrels
Figure 5: After the composite is cured, the Veriflex™ mandrel is heated abo e its activation above acti ation temperature. temperat re The Veriflex™ Verifle ™ 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 mandrel, which returned to its "memory" memory shape while above its transition temperature, can be reused. ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
60
Creel tensioners
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
61
Integral head resin wet wet-out out bath
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
62
Winding pins for low angle winding
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
63
Continuous curing oven
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
64
Layout of a computer-controlled filament winding machine filament-winding
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
65
Gas tanks
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
66
Aerospace parts
F-16
Patriot missile
Soviet missile
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
67
Tape laying – 787 fuselage
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
68
Tape laying – 787 fuselage
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
69
Composite motors
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
70
Sporting p gg goods
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
71
Glass epoxy filament-wound 9-foot-diameter by 55-footlong assembled railway tank car
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
72
Pipe machine and cure oven
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
73
Light g p pole
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
74
Thermoplastics processing
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
75
Injection molding Clamp l
Mold ld
Barrell Hopper
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
76
Injection molding pellets clamp
nozzle
hopper
barrel
throat
mold cavityy
screw
heaters
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
motor / drive
77
Roll forming
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
78
Roll-formed part
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
79
Matched die forming adjustment bolts
sample and holder
alignment pins
weights
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
80
Press forming g of LDF (long discontinuous fibers)
Heat material
Transfer into heated dies
Clamp and thermoform
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
Formed component after trimming
81
Compression molding
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
82
Compression molding sequence
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
83
Hydroforming
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
84
Diaphragm forming
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
85
Diaphragm forming
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
86
Vacuum forming in autoclave
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
87
Stretch forming
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
88
Tape laying
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
89
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
90
Automated Tow Placement - Thermoplastics
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
91
Robotic thermoplastic ATP machine
NASA Langley ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
92
Filament winding thermoplastic ATP machines hi
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
93
Filament winding thermoset ATP machine
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
94
Large ATP machine
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
95
Typical parts
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
96
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
97
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
1
Definition • A microscopic mixture of two or more different materials. materials One typically being the continuous phase (matrix), and the other being the discontinuous phase (reinforcement). • Its It properties ti are strongly t l dependent d d t on the composite structure. • Ductility of matrix combined with stiffness of reinforcement. ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
2
Ceramic fiber composite Polymer matrix composite ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
3
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))
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
4
Fibers/Particles Reinforcement • • • • • • • • •
Glass Kevlar Carbon Thermoplastics Alumina Boron SiC Steel Si3N4
• • • • • •
Silica Glass beads Talc Rocks Carbon black Calcium carbonate
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
5
Reinforcements
• Rovings – continuous – bulk
• Continuous strand mat • Chopped strand mat • Surface veils ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
6
Matrices • Protects & separates reinforcement, transmits forces • Polymer – PEEK, PEEK epoxy, polyester, l polyurethane, l h rubber bb
• Metal – Al, Al C Cu, Ni Ni, Ti
• Ceramic – glass, glass cement
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
7
Honeycomb composites
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
8
C 17 Aircraft C-17
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
9
Visby Corvette
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
10
IsoTruss Bike
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
11
Processes • Hand lay-up • Vacuum V b bagging/autoclave i / l • Compression molding – SMC/BMC
• Liquid resin molding • Resin transfer molding
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
12
Processes • • • • •
Pultrusion Filament winding Injection molding Th Thermoplastics l ti processing i Automated tape laying
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
13
Manual lay lay-up 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
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
14
Hand spray spray-up up
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
15
Hand lay lay-up up shop
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
16
Molds
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
17
Mold
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
18
Vacuum bag assembly
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
19
Vacuum bag Breather Bleeder
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
20
Lay-up y p Material i l on stiffening iff i structure
Vacuum bag and fittings attached ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
21
Autoclave
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
22
Autoclave
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
23
Delta II Rocket
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
24
Delta II rocket
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
25
Can be used with bulk molding g compound p ((BMC)) ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
26
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
27
Schematic of a compression molding press
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
28
Car parts with Sheet Molding Compound (SMC) - Prowler
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
29
SMC manufacture using a configuration that can make chopped-fiber SMC-R; continuous fiber SMC-C; or continuous, random SMC-C/R material
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
30
Molding process
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
31
Fiber orientation
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
32
Resin transfer molding (RTM) process
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
33
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
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
34
Car parts
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
35
RTM automobile t bil structure t t
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
36
Truck
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
37
Train Compartment
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
38
Train Compartment p
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
39
Plenum method for making preforms
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
40
Schematic of high-speed RTM process
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
41
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
42
SCRIMP – Boat Hulls
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
43
Pultrusion process p
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
44
Fiber let-off let off
Preforming
Curing die
Cut-off saw
Fiber guides
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
Resin impregnation
45
Puller
Reinforcements
• Rovings – continuous – bulk
• Continuous strand mat • Chopped strand mat • Surface veils ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
46
Continuous fiber reinforcement pultusion
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
47
Hollow structure pultrusion process
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
48
RIM (Reaction Injection Molding) pultrusion
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
49
Exploded view of pultruded composite
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
50
Bank of America Building Spire
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
51
Pultruded bridges g
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
52
Pultruded I-beam
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
53
Filament winding g
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
54
GT’s machine
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
55
Filament winding g machines
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
56
Delta IV Rocket faring g mandrel
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
57
Reusable Mandrels
Figure gu e 1: A Veriflex™ e e cy cylinder de is s fabricated. ab cated
Figure 2: The cylinder is placed in a clamshell mold mold, heated, and blow-molded into a complex-shaped mandrel. ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
58
Reusable Mandrels
Figure 3: The mandrel is cooled below the transition temperature resulting in a rigid mandrel.
Figure 4: The mandrel is filament-wound filament wound and then cured cured. The cure process for the composite does not affect the mandrel. ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
59
Reusable Mandrels
Figure 5: After the composite is cured, the Veriflex™ mandrel is heated abo e its activation above acti ation temperature. temperat re The Veriflex™ Verifle ™ 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 mandrel, which returned to its "memory" memory shape while above its transition temperature, can be reused. ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
60
Creel tensioners
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
61
Integral head resin wet wet-out out bath
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
62
Winding pins for low angle winding
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
63
Continuous curing oven
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
64
Layout of a computer-controlled filament winding machine filament-winding
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
65
Gas tanks
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
66
Aerospace parts
F-16
Patriot missile
Soviet missile
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
67
Tape laying – 787 fuselage
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
68
Tape laying – 787 fuselage
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
69
Composite motors
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
70
Sporting p gg goods
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
71
Glass epoxy filament-wound 9-foot-diameter by 55-footlong assembled railway tank car
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
72
Pipe machine and cure oven
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
73
Light g p pole
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
74
Thermoplastics processing
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
75
Injection molding Clamp l
Mold ld
Barrell Hopper
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
76
Injection molding pellets clamp
nozzle
hopper
barrel
throat
mold cavityy
screw
heaters
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
motor / drive
77
Roll forming
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
78
Roll-formed part
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
79
Matched die forming adjustment bolts
sample and holder
alignment pins
weights
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
80
Press forming g of LDF (long discontinuous fibers)
Heat material
Transfer into heated dies
Clamp and thermoform
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
Formed component after trimming
81
Compression molding
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
82
Compression molding sequence
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
83
Hydroforming
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
84
Diaphragm forming
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
85
Diaphragm forming
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
86
Vacuum forming in autoclave
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
87
Stretch forming
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
88
Tape laying
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
89
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
90
Automated Tow Placement - Thermoplastics
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
91
Robotic thermoplastic ATP machine
NASA Langley ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
92
Filament winding thermoplastic ATP machines hi
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
93
Filament winding thermoset ATP machine
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
94
Large ATP machine
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
95
Typical parts
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
96
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009
97
Related Documents
Composites Processing
June 2020 10
Composites
May 2020 11
Thermoplastic Composites
November 2019 12
Marine Composites
June 2020 32
17 Composites
May 2020 18