Composite Manufacturing Methods

12 Key excerpts on "Composite Manufacturing Methods"

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  Characterization, Testing, Measurement, and Metrology

  • Chander Prakash, Sunpreet Singh, J. Paulo Davim, Chander Prakash, Sunpreet Singh, J. Paulo Davim(Authors)
  • 2020(Publication Date)
  • CRC Press

    (Publisher)

  7   Fabrication and Machining Methods of Composites for Aerospace Applications Atul Babbar Shree Guru Gobind Singh Tricentenary University, Gurugram, Haryana, India Vivek Jain, Dheeraj Gupta Thapar Institute of Engineering and Technology Chander Prakash Lovely Professional University Ankit Sharma Chitkara University CONTENTS 7.1     Introduction 7.2     Composites 7.2.1     Types of Composites 7.2.1.1     Metal Matrix Composite (MMC) 7.2.1.2     Polymer Matrix Composite (PMC) 7.2.1.3     Ceramic Matrix Composites (CMCs) 7.3     Methods of Preparation of Ceramic Matrix Composite 7.3.1     Polymer Infiltration and Pyrolysis (PIP) 7.3.2     Reaction Bonding 7.3.3     Hot Pressing 7.3.4     Chemical Vapour Infiltration 7.4     Processing of Fibre-​Reinforced CMC via CVI Process 7.4.1     Processing of CMCs 7.4.1.1     CVI Reactor 7.4.2     Types of CVI Processes 7.4.2.1     Isothermal-​Isobaric Infiltration 7.4.2.2     Thermal Gradient 7.4.2.3     Pressure Gradient 7.4.2.4     Film Boiling 7.5     Rotary Ultrasonic Machining (RUM) 7.5.1     Background of RUM 7.6     Case Studies 7.7     Conclusion References

  7.1   Introduction

  The engineering industry has been constantly evolving over the years through several innovations and inventions. The increase in the number of complex engineering applications has led to the development of many advanced materials such as advanced ceramics and high strength temperature-​resistant (HSTR) alloys. [1 ]. The modern engineering industries are constantly dealing with these advanced materials to transform them to suit the various applications. The process of transforming these materials involves various forms of material removal from them. The material removal from these advanced materials is a great challenge faced by the modern engineering industry.

  Among the advanced materials, ceramics have extensive applications due to their superior wear resistance and refractoriness [2 ]. The most important characteristic of ceramics that possess difficulty in machining is the brittleness or the fragile nature of the ceramics which causes them to crack easily while machining. Furthermore, they are also prone to thermal cracking at high temperatures that arise during the machining process at the tool–work interface due to the high-temperature gradient that develops in their structure [3 ]. Machining of material can be generally categorized into two categories: conventional (traditional) and non-​conventional machining. Conventional machining contains direct contact of workpiece and tool [4 ]. However, highly brittle and hard material is difficult to machine by conventional machining techniques such as turning, drilling, and shaping [5 ]. Nonconventional machining processes have surpassed the limitations associated with conventional machining processes. In recent years, rotary ultrasonic milling has emerged as a technique which can machine the material with superior machining characteristics. It provides decreased cutting force, lesser generation of heat, and increased tool life [6

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  Composites Manufacturing

  Materials, Product, and Process Engineering

  • Sanjay Mazumdar(Author)
  • 2001(Publication Date)
  • CRC Press

    (Publisher)

  This lower-energy requirement in the pro- cessing of composites as compared to metals offers various new opportuni- ties for transforming the raw material to near-net-shape parts. There are two major benefits in producing near-net- or net-shape parts. First, it minimizes the machining requirement and thus the cost of machin- ing. Second, it minimizes the scrap and thus provides material savings. There are cases when machining of the composites is required to make holes or to create special features. The machining of composites requires a different approach than machining of metals; this is discussed in Chapter 10. 100 Composites Manufacturing: Materials, Product, and Process Engineering Composite production techniques utilize various types of composite raw materials, including fibers, resins, mats, fabrics, prepregs, and molding com- pounds, for the fabrication of composite parts. Each manufacturing tech- nique requires different types of material systems, different processing conditions, and different tools for part fabrication. Figure 1.5 in Chapter 1 shows a list of the various types of most commonly used composites man- ufacturing techniques and Figure 2.1 in Chapter 2 shows the type of raw materials used in those manufacturing techniques. Each technique has its own advantages and disadvantages in terms of processing, part size, part shapes, part cost, etc. Part production success relies on the correct selection of a manufacturing technique as well as judicious selection of processing parameters. The main focus of this chapter is to describe emerging and commercially available manufacturing techniques in the field of thermoset- and thermoplastic-based composite materials. Various composites manufac- turing techniques are discussed in terms of their limitations, advantages, methods of applying heat and pressure, type of raw materials used, and other important parameters.

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  Biomedical Composites

  • Luigi Ambrosio(Author)
  • 2017(Publication Date)
  • Woodhead Publishing

    (Publisher)

  2

  Design and fabrication methods for biocomposites

  L.K. Cardon* ; K.J. Ragaert* ; R. De Santis† ; A. Gloria†     

  * Ghent University, Ghent, Belgium† Institute of Polymers, Composites and Biomaterials, National Research Council of Italy, Naples, Italy

  Abstract

  Some basic concepts in construction of biocomposites are discussed, such as the different types of biocomposites, the composing material classes, and the general families of production techniques. The conventional, solution-based, and additive manufacturing processing technologies for biocomposites are described and their applicability and base material requirements, i.e. whether they employ solutions or the undiluted composites/compounds are explored. The technologies discussed include extrusion/injection, filament winding, compression, autoclaving, infusion, solvent casting, phase separation, electrospinning, and solid freeform fabrication. Every section elaborates on the named production process itself and the resulting biocomposite construct, offering an indication of which technique is most appropriate for given product demands. The influence of the processing parameters on the composite material is evaluated, and some relevant design examples are presented. In conclusion, a comprehensive overview of the different techniques and their applicability is presented in tabular form.

  Keywords

  Biocomposites; Design and fabrication methods; Processing parameters; Scaffolds; Tissue engineering.

  2.1 Introduction

  Biocomposite structures are either parts made of biomaterial compounds with a filler element dispersed into the matrix material, or a construct with alternating sections of different materials (Fig. 2.1

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  Process Modeling in Composites Manufacturing

  • Suresh G. Advani, E. Murat Sozer, Suresh G. Advani, E. Murat Sozer(Authors)
  • 2010(Publication Date)
  • CRC Press

    (Publisher)

  Chapter 2 Overview of Manufacturing Processes 2.1 Background Several industries have been using fiber reinforced composite materials for a few decades now. Glass fibers were available commercially in the 1940s. Within a decade, composites were being used by several industries; for example, the automobile industry was producing polyester panels with approximately 25% glass fibers [26]. Manufacturing with composite materials is very different from metals. This is because when making a metal part, the properties of the virgin material and the finished part are fundamentally unchanged. For composites, the manufacturing process plays a key role. During composite processing, one makes not only the part of the desired shape, but also the material itself with specific properties. In addition, the quality of the composite material and the part fabricated depends on the manufacturing process, because it is during the manufacturing process that the matrix material and the fiber reinforcement are combined and consolidated to form the composite. In early stages of development, the cost of composite materials was very high and only selected industries, for which the importance of the property of the material greatly out-weighed the cost factor, were willing to use them. These industries were primarily the aerospace and the aeronautical industries. They valued the properties of the composites greatly and could justify the higher costs because of the weight savings. Both industries took advantage of the light weight and, in the case of defense oriented projects, the stealth properties. The lack of automated and repeatable manufacturing processes drove the cost of composite parts up and limited the number of potential users. Another industry that has been using composites since the 1970s is the marine industry. It could deal with low pro-duction volume and relatively high costs while taking advantage of the corrosion resistance property of composites.

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  Failure Analysis of Composite Materials with Manufacturing Defects

  • Ramesh Talreja(Author)
  • 2024(Publication Date)
  • CRC Press

    (Publisher)

  2 Manufacturing Methods for Polymer Matrix Composites (PMCs)

  DOI: 10.1201/9781003225737-2

  2.1 Introduction

  While the synergistic nature of composite materials offers many advantages over monolithic materials, polymer matrix composites (PMCs) are the most used composites due to the low mass density of polymers and the consequent high specific properties such as stiffness and strength per unit of weight when measured in principal (reinforcement) directions. Driven by the requirements of PMCs for aerospace and a wide range of non-aerospace applications, polymers have been developed to contribute to the structural properties of composites as well as to allow the manufacturing of structural geometries within cost constraints. Thus, from the early applications in boats and pipes, where polyester was the common polymer used in a wet layup with E-glass fibers, today advanced thermoplastics are used in additive manufacturing processes. With each combination of fibers, fiber architecture, process type, and process parameter history (e.g., time variation of temperature and pressure), the composite material resulting at the end of the process is a “product” of that combination. The internal composition of that material dictates the structural performance under service. This book is concerned with the role of manufacturing-induced defects on that performance. For that purpose, it is necessary to understand the nature of the defects and how they result from the manufacturing processes. With that in mind, this chapter will review the common manufacturing methods and the type of defects they produce. For more extensive reviews of PMC manufacturing, see [1 , 2 , 3 , 4 ].

  2.2 Practical PMC Manufacturing vs Manufacturing Science

  There is a distinction between manufacturing science and practical manufacturing. This distinction is important from the perspective of manufacturing defects. In manufacturing science, the objective is to clarify, and possibly predict, the formation of deviations from the intended composite internal structure as a function of the process parameters. In simulating the manufacturing process using the processing parameters it is difficult to account for human intervention which is still present to a significant extent in practical PMC manufacturing. To what extent this intervention is necessary depends on the type of manufacturing and its cost constraints. Automated manufacturing is an increasing trend and in this type of process it is possible to quantify the process parameters and control them to some extent. This then allows conducting realistic modeling and simulation studies.

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  Parts Fabrication

  Principles and Process

  • Richard Crowson(Author)
  • 2006(Publication Date)
  • CRC Press

    (Publisher)

  This approach will require fundamental work in the structure of matter and will be of a long-term nature. Second, more effective manufacturing technologies and processes must be utilized in order to reduce the cost associated with current technologies. 6.0.1 Design/Manufacturing Interface In today’s competitive cost environment, the producibility of a new design is not merely important—it is the key to survival as a leader in the field of manufacturing. Many authorities would agree that perhaps as much as 90% of the ultimate cost of a product may be predicated by the design, and only 10% can be influenced by the manufacturing process. However, by considering the known production processes, the quality and reliability inherent in the process, and the material selections available within the constraints of product function, we can optimize a design early in the devel-opment of a new or revised product. This is certainly true in the field of composites. In common with other manufacturing processes, the fabrication of composites may be conveniently discussed in terms of the labor, materials, tooling, and equip-ment requirements. Quite straightforward design changes can sometimes lead to great cost savings in manufacturing. Structures perfectly acceptable in metals may be difficult or impossible to fabricate in composites. For example, the flanges on the outer duct of an aircraft engine may be fabricated in metal using standard shop practices, but are a real challenge in carbon fiber-reinforced plastic. Here it is good to bear in mind that there may be little to be gained but a good deal to be lost by dogmatic adherence to a particular “all-composite” philosophy. If a particular struc-ture or part of a structure would be easier to fabricate in metals, then the smart com-promise is to combine the materials to meet design requirements at minimum cost. Failure to recognize this can lead to program delays and very substantial cost over-runs.

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  Design and Manufacture of Textile Composites

  • A C Long(Author)
  • 2005(Publication Date)
  • Woodhead Publishing

    (Publisher)

  6

  Composites manufacturing – thermoplastics

  M D WAKEMAN and J-A E MÅNSON,     École Polytechnique de Fédérale Lausanne (EPFL), Switzerland

  Publisher Summary

  Thermoplastic composites offer increased recyclability and can be post-formed or reprocessed by the application of heat and pressure. A large range of tough matrix materials is also available. The manufacture of components from textile thermoplastic composites requires a heating process, either directly before the final molding process, where an oven plus a cool tool is used (non-isothermal processing), or in a hot mould (isothermal processing). Heat transfer forms the principal boundary condition governing process cycle times, with a corresponding potential for lower conversion costs. These basic steps define the many processing techniques that can be used to transform different material forms into the final product, where considerable flexibility exists to heat and shape the textile composites. One limitation for manufacturing techniques that result from the continuous, well-ordered, and close-packed fiber architectures is that these materials do not flow in the same way as a fiber suspension to fill a tool, but must instead be deformed by draping mechanisms. However, this limitation notwithstanding, a wide variety of both materials and processing techniques have been developed for both niche applications and components produced at high volumes. This chapter provides an overview of the impregnation and consolidation processes for thermoplastics that have driven both materials development and the choice of final conversion process. It presents a summary of thermoplastic composite pre-impregnation manufacturing routes and a review of final conversion processes for textile thermoplastic composites. The chapter also reviews forthcoming processing techniques for hybrid textile composite structures.

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  Metal Additive Manufacturing

  • Ehsan Toyserkani, Dyuti Sarker, Osezua Obehi Ibhadode, Farzad Liravi, Paola Russo, Katayoon Taherkhani(Authors)
  • 2021(Publication Date)
  • Wiley

    (Publisher)

  from the individual components. As the individual component remains distinct and separates in the final structure, composites can be distinguished from the mixture of materials and solid solutions. Generally, composites are comprised of three parts; (i) matrix as an incessant phase, (ii) reinforcing elements as inhomogeneous or distributed phases, and (iii) an interfacial bound-ary or binder. Through the appropriate selection of component materials and manufacturing techniques, the mechanical performance of composites as well as their material and structural characteristics can be selectively designed. The new material may be selected for desirable properties such as lower thermal expansion coefficient, higher wear resistance, greater com-pressive strength, tensile strength, flexibility, and hardness. 9.2 Conventional Manufacturing Techniques for Metal Matrix Composites (MMCs) There is a wide variety of manufacturing techniques available for MMCs. Based on the proces-sing temperature of the matrix material, the conventional techniques of MMCs are generalized into four as follows: i. Liquid-phase methods : mixing liquid metal matrix and ceramic reinforcements; melt infiltration; squeeze casting or pressure infiltration; reaction infiltration; and melt oxidation process. ii. Solid-phase methods : powder metallurgy techniques such as pressing followed by sinter-ing, forging, and extrusion; higher energy and higher rate methods; diffusion bonding; and plastic deformation processes such as friction stir welding and superplastic forming. iii. Solid/liquid dual-phase methods : rheo-casting/compo-casting; and variable co-deposition of multiphase materials. iv. Deposition methods : spray deposition; chemical vapor deposition (CVD); physical vapor deposition (PVD); and spray forming processes.

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  Soft Computing in the Design and Manufacturing of Composite Materials

  Applications to Brake Friction and Thermoset Matrix Composites

  • Dragan Aleksendric, Pierpaolo Carlone(Authors)
  • 2015(Publication Date)
  • Woodhead Publishing

    (Publisher)

  3

  Composite materials manufacturing

  Abstract

  The manufacturing process is very important with regard to the final properties of a composite material. The manufacturing processes employed to realize brake friction materials or thermoset matrix composites have a crucial impact on their future properties. This is especially related to the level and stability of friction and wear during braking in the case of brake friction materials. The development of a composite material is strongly affected by its formulation and its manufacturing conditions. Owing to the complex and interrelated influences of the formulation and the manufacturing conditions, it is difficult to find the best set of process parameters for a specific material formulation. Accordingly, the selection, mixing and preparation of raw materials, as well as the choice of moulding pressure, moulding time, moulding temperature, heat treatment time and/or heat treatment temperature, can be done over a wide range. In this chapter, the basic characteristics of the manufacturing processes for brake friction materials and thermoset matrix composites are elaborated on.

  Key words manufacturing process thermoset matrix composite brake friction material manufacturing conditions disc pad

  3.1 Manufacturing of thermoset matrix composites

  3.1.1 Introduction

  In recent years, polymeric matrix composite materials have been widely used for several applications in different fields, such as automotive, aerospace, aeronautical, nautical, energy and sporting goods. The demand for high performance and constant quality, combined with the need to reduce costs arising from any possible manufacturing inefficiencies, has resulted in the increasing use and development of industrial manufacturing processes characterized by low human intervention [1 ]. In several cases, a reduction in human presence is also strongly desirable to avoid health hazards caused by the emission of volatiles during the resin reaction, such as, for instance, styrene emission during the curing process of polyester resins [2

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  Chemical Methods for Processing Nanomaterials

  • Vidya Nand Singh(Author)
  • 2021(Publication Date)
  • CRC Press

    (Publisher)

  HAPTER 6Methods of Manufacturing Composite Materials

  Anton Yegorov,

  1 ,2

  * Marina Bogdanovskaya,

  1 ,2

  Vitaly Ivanov,

  1 ,2

  and Darla Aleksandrova

  1 ,2

       

  The widespread use of composite materials, especially polymer composite materials (PCM), has made enormous progress in the field of polymer chemistry and physics. Today, the most popular composite materials are PCM based on continuous carbon and glass fibers. Such fillers for polymer materials as carbon nanotubes (CNT), fullerenes, and other nanoobjects, are not far behind in terms of the growth of technology.

  This chapter discusses approaches for the formation of polymer composite materials, especially the production of composites based on high-temperature thermoset plastics based on polyimides. In particular, the research will allow improving the latest trend in additive technologies — 3D printing of composite materials reinforced with continuous fibers, which makes possible to manufacture designs with high stiffness.

  1. Introduction

  The widespread use of composite materials, especially polymer composite materials (PCM), has made tremendous progress in the field of polymer chemistry and physics. Today, the most popular are PCM based on continuous fibers, rovings, and fabrics. Such fillers of polymeric materials as carbide fibers, carbon nanotubes (CNT), fullerenes, and other nanoobjects, are not far behind in terms of the growth rates of technologies.

  The increased interest in obtaining nanocomposites is associated with the unique effect of nanoscale filler on the bulk properties of polymer composites [1 , 2 ]. In addition, the introduction of nanoscale filler in the polymer matrix results in materials with high rigidity, toughness, and tribological properties [3 ].

  2. Brief Description of Polymer Composite Materials

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  Metal Matrix Composites

  Thermomechanical Behavior

  • Minoru Taya, Richard J. Arsenault(Authors)
  • 2016(Publication Date)
  • Pergamon

    (Publisher)

  CHAPTER 6 Engineering Problems 6.1 Introduction In order to characterize the thermomechanical behavior of a metal matrix composite, the metal matrix composite must be first fabricated by an appro-priate processing route, followed by machining it into a specimen geometry. Then the machined metal matrix composite specimen will be subjected to thermal and mechanical tests to determine its thermomechanical behavior, so that the experimental thermal-mechanical properties can be compared with those predicted by analytical models. In this chapter some of the engineering problems relevant to the thermo-mechanical behavior of a metal matrix composites will be discussed. These include fabrication and machining. Of these, fabrication appears to be the most popular, as evidenced by the large number of papers written on this subject. However, quite recently fabrication has been studied rigorously from the scientific viewpoint, i.e., in terms of simulation by an appropriate thermo-mechanical model. A brief review of the recent fabrication studies, with a scientific approach, will be made here. Unlike fabrication studies, there has not been much focus on machining of metal matrix composites despite the fact that all the metal matrix composites fabricated must be machined for use as structural components or characterization by thermal and mechanical tests. Also, the machining cost often represents a large portion of the total cost of a metal matrix composite component. Hence, machinability studies of metal matrix composites should not be overlooked. 6.2 Fabrication Fabrication methods for the production of metal matrix composites have been revived recently as one of the thrust areas of composite technology, and a number of books have focused on the fabrication methods for metal matrix composites; for example, books by Kelly and Mileiko [1] and Schwartz [2].

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  Composites and Their Properties

  • Ning Hu(Author)
  • 2012(Publication Date)
  • IntechOpen

    (Publisher)

  Section 3 Design, Processing, and Manufacturing Technologies Chapter 10 © 2012 Laurenzi and Marchetti, licensee InTech. This is an open access chapter distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/3.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. Advanced Composite Materials by Resin Transfer Molding for Aerospace Applications Susanna Laurenzi and Mario Marchetti Additional information is available at the end of the chapter http://dx.doi.org/10.5772/48172 1. Introduction Competitiveness drives the aerospace industries to investigate new technology solutions to address market pressure and high-tech demands. The global objective is to reduce to half the amount of fuel by 2020 and at least 70% less by 2025 with respect to the Boeing 777, one of the most efficient aircraft, which is made entirely of carbon fiber. The weight saving to increase payload and the reductions of the cost/time of the production cycle are imperative targets. For these reasons, aerospace companies, which are traditionally based on the use of metal alloys, have been focusing for past decade on composite materials. The main advantages of composites with respect to metals, that are resistance to corrosion and fatigue and high performance/weight ratios, are a set of qualities for winning the current and future aerospace applications. Obviously, this is possible only through the development of economically competitive technologies. The Resin Transfer Molding (RTM) is one of the most promising technology available today. RTM is capable of making large complex three-dimensional part with high mechanical performance, tight dimensional tolerance and high surface finish. A good design by RTM leads to fabricate three-dimensional near-net-shape complex parts, offering production of cost-effective structural parts in medium-volume quantities using low cost tooling.

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