玻璃钢制品工15

CompositesManufactureThereareno‘offtheshelf’properties-thematerialismadeatthesametimeasthepart.HandLay-up

spraygelcoatapplicationHandLay-up

applicationofgelcoatbyrollerHandLay-up

applicationofreinforcementHandLay-up

applicationofreinforcementHandLay-up

applicationofresinandconsolidationHandLay-up

furtherconsolidationHandLay-up

additionofwovenplyChopperheadforspray-upSpray-upequipmentSprayapplicationonexistinggelcoatSprayapplication

offibreandresinConsolidationaftersprayapplicationAdvantagesofHandLay-upLowcosttoolingLowcostmaterialsLargepartspossibleLowtechnologyRoom-temperaturecureDisadvantagesofHandLay-upLaminatequalitydependentonoperatorskill.Poorworkingenvironment.HealthandsafetyissuesassociatedwithstyreneAdvantagesofSprayLay-upLowcosttooling.Rapiddeposition.MatureindustryDisadvantagesofSprayLay-upResin-richlaminates.Onlyshortfibrescanbeused.Lowviscosityresinsrequired(inferiorproperties).Healthandsafetyimplicationsofstyrene.Highwastage.Handlay-upMaterialsoptions:Anythermosettingresin.Anyreinforcement(someheavyfabricshardtowet-out)Applications:ProductionboatsWaterstoragetanksArchitecturalmouldings.Spraylay-upMaterialsoptions:Generallypolyester.GlassrovingonlyApplications:SmallproductionboatsEnclosuresVehiclebodypanels.EffectofvoidsonpropertiesSourcesofvoidsLayersofairtrappedbetweenpliesDissolvedairorvolatilesemergingfromsolutionResinshrinkageoncurePoorwettingoffibresurfaceLackofimpregnationEffectofconsolidationpressureonvoidsVacuumBagMouldingUsescontactmould.Wetlayuporspecialist‘prepreg’materials-usuallyepoxyandotherhighperformance,longcuretimeresins.Roomtemperaturecureorovencureundervacuumonly.Autoclavecureunderpressureforhighestqualitylaminates.Processschematic

(SPSystems)VacuumbaggingPreparationofcarbon/epoxyprepregVacuumbaggingHandlay-upoftailoredprepregVacuumbaggingApplicationofpeel-plytobackoflaminate.GivescleantexturedsurfaceforsubsequentbondingorpaintingVacuumbaggingApplicationofreleasefilm(semi-porous)VacuumbaggingBreathermataddedtolayup.Sealanttapeappliedtomouldflanges.VacuumbaggingNylonbaggingfilmattachedtosealanttape.Pleatsensureexcessbagtoconformtomouldcontours.VacuumbaggingVacuumconnectionattachedthroughbaggingfilm.VacuumbaggingVacuumapplied-checkforleaksandensureconsolidation.Completedlayupreadyforcurecycle.40mwindturbineblade.Plywood/epoxywetlayuppriortovacuumbagging.40mwindturbineblade.Applicationofvacuumbag.EffectofconsolidationpressureonvoidsCompositepanelbeingloadedintoautoclave.VacuumbaggingDisadvantagesHighcostandstoragerequirementsofprepregs.Highlabour/skillcontent.Costofconsumables.Capitalcostofoven/autoclave.AdvantagesHighqualitycompositeparts.Largesizespossible.Relativelylowcost,lightweighttooling.Cleanmanufacturingenvironment.VacuumbaggingapplicationsJECCompositesMay2003Autoclavetechnology:

“Lengthdoesn’tmatter”.

Costincreasesexponentiallywithdiameter.Hoopstressd;endloadd2AeroformLtd12msparforA400(resinfilminfusion)GKNWestlandAerospaceMANUFACTUREOFPOLYMERCOMPOSITESBYCOMPRESSIONMOULDINGCompressionmouldingMaterialsoptions:Dryreinforcement/liquidresinPolyesterandphenolicresinmouldingcompound(SMC,BMC…)EpoxyprepregsApplications:Carandtruckbodypanels,enginecomponentsElectricalhousingsBuildingcladdingpanelsHighprecisionopticalpartsTypicalcompressionmouldingpressColdpressmoulding

dryfibre/liquidresinColdpressmoulding

dryfibre/liquidresinColdpressmoulding

dryfibre/liquidresinSheetmouldingcompoundTruckbodypartscompressionmouldedfromSMCAdvancedcompositepartsfromcompressionmouldedcarbonprepreg(heatedtooling)recorddecktonearmmoviecamerayachtsteeringgearsafetyhelmetCompressionmouldingAdvantages:RapidcycletimeswithpolyesterSMCExcellentsurfacefinishinheatedtoolingHightolerancesLowmaterialwasteDisadvantages:HighcapitalinvestmentLimitedpresssizeHighcosttoolingResinTransferMouldingMatchedmouldtool-fixedcavity.Dryreinforcement‘preform’loadedintotool.Catalysedliquidresininjectedunderpositivepressure.RTMprocessschematic

(www.plastech.co.uk)RTMToolingTophalfBottomhalfRTM

LoadingthereinforcementpreformRTMClosingthetoolResininjectionRTM-partremovalRTM-FordTransitVanRoofPlastechThermosetTectonicsRTMApplicationsPlastechUniversityofPlymouthRTM-AdvantagesGoodthicknesstoleranceTwomouldedsurfacesHighfibrecontentpossibleReducedstyreneemissionPotentialforautomationRTM-disadvantagesExpensivetoolingSizelimitationsFlowpredictiondifficultPropertiesoflowviscosityresinsVacuumResinInfusionAlsoknownas:VARTMRIFTSCRIMPVacuumResinInfusionUsescontactmould.Dryreinforcementencapsulatedbysealedpolymericbagorlightweightlaminate.Catalysedresindrawnthroughreinforcementundervacuum.Processschematic

(SPSystems)VacuumresininfusionContactmouldtoolToolwithfibrematloadedVacuumresininfusionSemi-rigidtopattachedInfusionundervacuumResinInfusion-advantagesoverhandlay-upHigherqualitylaminateReducedstyreneemissionsCoredlaminatesinoneoperationResinInfusion-disadvantagesoverhandlay-upCarefulprocesscontrolrequiredMoreconsumablesLowviscosityresinrequiredResinInfusion-advantagesoverRTMMuchlowertoolingcostLessprocessingequipmentrequiredNosizerestrictionCanadaptexistinghandlay-uptoolingResinInfusion-disadvantagesoverRTMOnlyonemouldedsurfaceLesscontroloverpartthicknessInjectiontimelimitedby1barpressureFilamentWindingFilamentwinding

processschematicRawmaterial-continuousfibresFilamentwinding

continuousfibreimpregnation;windingontorotatingcurvedsurfaceundertensionAdvantagesofFilamentWindingRapidprocessHighlyautomatedControlledresincontentMinimumfibrecostHighfibrecontent-goodstructur