- Composites can be lighter than metals while maintaining strength in desired directions by not being isotropic. Composites contain two or more materials in different phases. - Common composite manufacturing processes include compression molding, resin transfer molding, hand lay-up, filament winding, and pultrusion. Process depends on fiber length and part geometry. - Fiber reinforcements include fiberglass, carbon fiber, and aramid fibers. Carbon fiber provides very high stiffness while aramid fiber is strong and impact-resistant. Fiber orientation affects composite strength and properties.

1. Reinforced Plastics

2. Composites
• Metals are isometric materials
• Composites can cut weight by not being
isometric and still maintain the strength in
the desired directions
• Composites are, by definition, solid
materials composed of more than one
substance in more than one phase

3. Composites

4. Processes
• Thermoplastic processes –Very short fibers
• Matched die/compression molding
• RTM
• Spray-up
• Hand lay-up for wet and prepreg materials
• Filament winding and fiber placement
• Pultrusion

5. Advanced Composites
• Long (continuous) fibers
• Very high performance reinforcements
– Carbon and aramid
• Resins are also very high performance
• Typically aerospace applications

6. Engineering Composites
• Shorter fibers/fiberglass
• Lower mechanical properties (stiffness)
• Lower performance resins

7. Matrix Materials
• Resins
– Both thermosets and thermoplastics can be
used
– Short fibers are generally used in
thermoplastics
– Long fibers are generally used with
thermosets

8. Matrix Materials
• Short fiber composites
– Less than 0.2 inches (whiskers)
– Processed through standard thermoplastic
processes
• Must pass through gates, runners, and gap
between processing screw and barrel walls
– Thermoplastics generally benefit greatly from
even the short reinforcement materials

9. Matrix Materials – FRP
• Intermediate length fiber reinforcement
– The longer the fibers, the more difficult it is to
coat the fibers enough to reap strength
benefits
– Low viscosity thermosets “wet-out” the
materials better than high viscosity
thermoplastics
– Generally use unsaturated polyester and
vinylester resins for FRP

10. Matrix Materials – Advanced
• Very long fibers or continuous fibers
– Typically used with thermosets, also for “wet-
out” reasons
– Used generally in advanced composite parts
and have greater material property
requirements
– Generally use epoxy resins

11. Reinforcements
• Three main types of fibers
– Fiberglass
– Carbon fiber or Graphite
– Organic fibers, aramids (kevlar)

12. Fiberglass
• Spin molten glass
• Different types of glass can be made
– E-glass (improved electrical resistance)
– S-glass (high strength)
– C-glass (high chemical resistance)

13. Carbon or Graphite Fiber
• Originally some distinction was made—
now the two refer to the same material
• Made from PAN fibers, pitch or rayon
fibers
• Through heating, raw material looses most
non-carbon atoms in the chain
• Processing also aligns carbon chains
• Carbon fibers have very high modulus
(stiffness)

14. Organic Reinforcement Fibers
• Aramid fibers have greatest strength and
modulus properties of organic fibers
• Kevlar is the most commonly used aramid
fiber
• Aramids are strong and stiff but their
greatest value is in impact applications
– Front of airplane wings
– Armor applications

15. Reinforcement Forms
• Fiber manufacturers package the fibers on
spools called tows
• Fibers are generally converted to other
forms after manufacturing
– Chopped fibers (including whiskers)
– Mat (random)
– Woven fibers
– Tapes
– Prepregs

16. Manufacturing Methods
• Thermoplastic processes using short
fibers
– Injection molding
– Extrusion
– Minor changes are made to accommodate the
fiber reinforcements
• All gaps in flow path should be increased
• A resin viscosity decrease may be necessary

17. Manufacturing Methods
• Matched die or Compression molding
– Reduced flow path over injection or extrusion
– SMC compression molding allows for
continuous fibers, mats or weaves
– These processes offer parts that are finished
on both sides where most other composite
processes do not

18. Manufacturing Methods
• Resin transfer molding
– Fiber preform is placed in the mold cavity
– Preform doesn’t move—resin is pulled/pushed
in

19. Manufacturing Methods
• Spray-up
– Fibers are chopped, coated with resin and
sprayed onto the mold

20. Manufacturing Methods
• Hand Lay-up (wet and prepreg)
Prepreg
Wet

21. Fiber Orientations
• Isometric materials have equal strength in
all directions
• Composites can be lighter weight by not
having strength in the directions that it is
not needed
• Lay-up still has to have some balance and
symmetry

22. Vacuum Bagging
• Provides for increased part consolidation
• Reduces matched die mold costs

23. Manufacturing Methods
• Filament winding and fiber placement
– Fiber placement has greater accuracy
– Fiber placement can wind on less symmetrical
and even partially concave mandrels
• Tubes, tanks, wind turbine blades and
rockets

24. Manufacturing Methods
• Roll wrapping
– Faster than filament winding
– Limited to symmetrical mandrels

25. Manufacturing Methods
• Pultrusion
– High volume production
– Comparable to extrusion but the main
processing force is tension
– Profile is pulled from the machine

26. Plant Concepts
• Many of the processes require
considerable space
• Curing equipment for large parts can be
very large (and expensive)
• Controlling volatiles (solvents and resins)
must be taken care of
• Molds can be both expensive and fragile

27. Thank You