Introduction to Composite IntroductiontoComposite

MaterialsandStructures
Nachiketa Tiwari NachiketaTiwari
IndianInstituteofTechnologyKanpur
Lecture11
ManufacturingofThermoset
Composites
BagMolding g g
Bagmoldingtechniqueworkswellwithwetformingprocess,andalso g g q g p ,
withpremix/prepreg formingprocess.Itisaveryold,andyetversatile
compositefabricationprocess.
Inthisprocess,layersoffibers,impregnatedwithuncuredresin,arelaid
ontopofamold,layerbylayer.Oncethelayupiscomplete,theoverall
fiberstackupiscoveredwithaflexiblebagordiaphragm.
The overall assembly is next subjected to external pressure and Theoverallassemblyisnextsubjectedtoexternalpressureand
temperatureforpurposesofreliablycuringtheresininrelativelyshort
periodoftime.
Oncecuringiscomplete,constituentmaterialsbecomeoneintegrated
mass in desired shape. They can subsequently trimmed, and finished, massindesiredshape.Theycansubsequentlytrimmed,andfinished,
followingwhichtheycanbeusedinactualapplication.
BagMolding g g
Layingupandproperbaggingofthematerialareverycriticalstepsinthe
entireprocess,astheyinfluencethequalityofpartproduced.Toensure
this,andelaboratesetupasshowninFig.11.1isrequiredforbagging.
As shown in this schematic, the layup is setup between a steel mold plate, Asshowninthisschematic,thelayupissetupbetweenasteelmoldplate,
andcaul plate,whicharecoatedwithasprayofreleasecoatfilm,aswell
asreleasefabric,whichensurethatthepartdoesnotgetstucktothe
moldplate.Thecompositepartiscoveredwithpeelplies,whichprotectit p p p p p , p
againstcontaminatingagents.Further,thelaminateisalsocoveredwith
bleederplies,whichabsorbexcessresin,andbreatherplies,whichactasa
pathwayforairbubblesandvolatilematerialstoexitoutfromthe p y
compositeduringcuring.Theentiresetupissealedinavacuumbagusing
appropriatesealants.
Inthisprocess,whileapplicationoftemperatureisrequiredtofastenthe
curingprocess,applicationofpressureisimportanttoensuregoodsurface
finish, dimensional accuracy, and also to eliminate presence of air and finish,dimensionalaccuracy,andalsotoeliminatepresenceofairand
porosityinthecompositecomponent.
Bag Molding BagMolding
Fig.11.1:TypicalBagMoldingProcessSetup g yp g g p
BagMolding g g
Bagmoldingprocesscanbecategorized,basedonthemethodof g g p g ,
applicationofexternalpressure,intothreegroups.
Pressurebagmolding:Herepressuresexceeding1barareappliedonthecomposite
materialbeingprocessed. g p
Vacuumbagmolding:Inthisprocess,thecompositematerialsissubjectedtovacuumto
removeairbubblesfromthelaminate.Postthisstage,thematerialmaybesubjectedto
atmosphericpressurewhileitundergoescuringprocessinanoven.
Autoclavemolding:Here,thecompositeissubjectedtovacuumpressures,andalso
elevatedpressuressimultaneously,whileitundergoescuringatelevatedtemperatures.
Inthisprocess,thepartisenclosedinabagconnectedtoavacuumpump.Further,the
exteriorofthebagissubjectedtopressuresexceeding1bar.Finally,curingoftheresin
is initiated through raising the temperature of material by placing it in an autoclave isinitiatedthroughraisingthetemperatureofmaterialbyplacingitinanautoclave
chamber.
In such a process application of high pressure ensures increased removal of air and Insuchaprocess,applicationofhighpressureensuresincreasedremovalofairand
othervolatiles,increasedwetting,andimprovedimpregnationoffiberswithresin.
BagMolding g g
Pressurebagmoldingisrelativelyexpensiveduetotoolingcosts.Inthis g g y p g
method,toolingisexpensivesinceitisintegratedwithcuringpressure
system.
Further,toolsforthistypeofbagmoldingarepartspecific.
Incontrast,vacuumbagandautoclavemoldingapproachesarerelatively
inexpensiveasthebasiccuringequipmentdoesnotchange.Figures11.2
and 11 3 are illustrations of these types of bag molding process and11.3,areillustrationsofthesetypesofbagmoldingprocess.
Bag Molding BagMolding
Fig.11.2:SetupforPressureBagMoldingProcess
Bag Molding BagMolding
Fig.11.3:SetupforVacuumBagMoldingProcess
ResinTransferMoldingg
ResinTransferMolding,commonlyknownasRTM,isawetprocess,where g, y , p ,
fibersandresinareplacedinthemoldseparately.
i l f fib ( /f b i ) l d i h ld l b First,layersoffibers(ormats/fabrics,)areplacedinthemoldlayerby
layer.Onceallthelayersoffibershavebeenplaced,pressurizedresinis
introducedinthemoldtoimpregnatethefibers.Themoldcavity,into
whichresinflows,hasinletsforresin,andalsoventsforair.
Once the mold is full of resin the system is heated to initiate curing Oncethemoldisfullofresin,thesystemisheatedtoinitiatecuring.
However,incertainapplications,curingmayoccuratroomtemperature.
Inthismethod,lowviscosityresinsarechosen,assuchresinswetfibers,
andalsoenterinterfibergapsrelativelyeasily.
ResinTransferMoldingg
RTMensureimprovedcontroloverfiberorientation,asfluidpressurein p , p
resinisnotsufficientlylargeenoughtodislodgefibersfromtheirintended
location.
Vacuumassistedresintransfermolding(VARTM)isavariationofRTM,
wherevacuumpressureaidsflowofresin,andalsowettingoffibers.
ComparedtoRTM,VARTMissignificantlylessexpensive.
R f References
1. Analysis and Performance of Fiber Composites, Agarwal,
B D d B t L J J h Wil & S B.D. and Broutman, L. J., John Wiley & Sons.
2 M h i f C i M i l J R M M G 2. Mechanics of Composite Materials, Jones, R. M., McGraw
Hill.
3. Engineering Mechanics of Composite Materials, Daniel, I.
M and Ishai O Oxford University Press M. and Ishai, O., Oxford University Press.