Công nghệ chế tạo các sản phẩm composites

(Manufacturing of composites)
Lecture 8
Công nghệ lăn ép
Lay-up process

Nguyễn Bá Kiên
Bộ môn CNVL-Khoa Cơ khí
nbkien@[Link]

2024
 Contents
➢ Composite Manufacturing Processes

➢ Công nghệ lăn ép bằng tay (Hand Lay up process)

➢ Process set up (thiết lập quy trình)

➢ Gel coat (lớp phủ gel)

➢ Advantages and Limitations (Các ưu điểm và hạn chế)

➢ Spray lay up process (Công nghệ phun ép)

2
 Processing Techniques

Primarily classified as:

➢ Structural applications – continuous aligned fibers

➢ Semi structural applications – continuous non aligned fibers

➢ Non structural applications – discontinuous fibers

3
Composites manufacturing

4
 Thermoset vs. Thermoplastic

Fibers +

Thermoset resin Thermoplastic resin

a) Liquid component A + liquid a) Solid matrix
component B b) Melting step
b) Impregnate fibers c) Impregnate fibers
c) Chemical reaction d) Cooling step
d) Solid matrix e) Solid matrix

5
Arrangement of fibers

[Link]

6
 Short vs. continuous fibers

Short fibers Continuous fibers

• Limited reinforcement • Hardly elongate
• Dimension stability at high • Must be placed
temperature • Properties can be tailored
• Quasi-Isotropic

7
Composites manufacturing methods
Thermoset Thermoplastic
• Resin Transfer Molding (RTM)
• Vacuum Infusion (VI)
• Vacuum Assisted Resin Transfer • Injection Molding
Short Molding (VARTM) • Compression Molding
Fibers* • Bulk Molding Compound • Sheet Molding Compound (SMC)
(BMC)

• Filament Winding – Robot • Filament Winding – Robot

• Tape-Laying – Automated Fiber • Tape-Laying – Automated Fiber
Continuous placement placement
fibers • Hand Lay-up • Hand Lay up + Autoclave
• Pultrusion • Stamping/Press Forming
• RTM/VI/VARTM
* Rarely used in aerospace

8
Composite Manufacturing Processes
Processes for Thermoseting matrix composites:
➢ Hand lay-up and spray up techniques.
➢ Filament winding
➢ Pultrusion
➢ Resin transfer moulding
➢ Autoclave moulding.

9
 Composite Manufacturing Processes
❖ Processes forThermoplastic matrix composites:
➢ Injection moulding
➢ Film stacking
➢ Diaphragm forming
➢ Thermoplastic tape laying

10
Composite Manufacturing Processes

[Link]

11
Performance comparison

[Link]

12
 Hand lay-up
➢ This is an open mold method of shaping to form a structure.
➢ Since the layers laid are in direct contact with atmosphere, it is called
an open mold process.
➢ It involves manual laying of fibers with resins on a mold by hands or
hand tools.
➢ Any type of fiber especially glass fiber is used.
➢ Thermoset resins in liquid form at room temperature e.g. epoxy,
polyester etc.
➢ The mold has shape of product and the product has the better surface
finish over the side that is in contact with the mold.

[Link]

13
 Hand lay-up

[Link]

14
 Hand lay-up

[Link]

15
 Hand lay-up
➢ Hand lay-up is mainly used for making FRP products in a mold.
➢ The mold has the shape of the product.
➢ The product will have smooth finish only on the side that is in contact
with the mold.
➢ Only the male or the female half of the mold is generally used in hand lay-up
process.
➢ The choice of male or female mold depends on which side of the product
needs good finish.
➢ If the inside surface needs smooth finish, then the product is made over a male
mold or vice versa.
➢ It is possible to make a product with glossy, mat, or textured finish on the
surface by using a mold with the respective finish.
➢ The mold must be free from surface defects,because the imprint of such defects
will form on the product.
16
Hand lay-up

[Link]
[Link]

17
Hand lay-up

[Link]

18
 Process set-up
➢ The first layer on mold is gel [Link] gives high surface quality.
➢ A release film is used to avoid the molded part from sticking to
the mold.
➢ A woven fiber layer laid with decided orientation.
➢ A layer of liquid resin is spread on the fibers laid earlier.
➢ The resin is mixed with some catalyst for introducing hardness
to the composite product.
➢ A brush is used to evenly spread the resin liquid.

19
 Process set-up
➢ The roller is used after laying each layer to remove the air
entrapped in the resin.
➢ This process is repeated until the required thickness is
acquired.
➢ The resin used requires curing for the hardening of its liquid form into
hardened product.
➢ Curing at room temperature may take days to complete and is used
for big sized products [Link] hulls.

20
 Gel Coat
• Gel coat is a thin layer of resin (∼0.5 mm thickness) applied over the
release film.
• Gel coat gives superior finish to the product.
• The required color of the product can be obtained by adding suitable
pigment to the resin.
• The gel coat serves the following purposes:
• It provides color,glossiness, and/or texture to the products.
• It conceals the fiber pattern.
• It also provides a resin-rich layer that protects the fiber from
getting in contact with water and chemicals.

21
 Advantages
➢ The large-scale use of hand lay-up process is attributed to the
simplicity of the process.
➢ No expensive equipment is required,and only simple inexpensive
➢ tools like brushes and rollers are needed.
➢ Practically there is no restriction on the size of the product.
➢ It is possible to mold all shapes and incorporate inserts of any shape.
Depending on the end user’s taste, colors and decorative finishes can
be incorporated in the product.
➢ This is the most suitable method for lining of tanks, ducts, and boats
and repairing of concrete structures.

22
 Limitations
➢ The process is labor intensive,and the quality of the product depends
largely on the skill of the person doing the fabrication.
➢ This process is not suitable if good surface finish is required on both
the sides of the product.
➢ This process cannot compete with compression molding for the mass
production of small items.
➢ Thickness control is not accurate and it is difficult to obtain uniform
fiber-to-resin ratio.

23
Spray lay up Process

[Link]

24
 Spray-Up Process
➢ Spray-up is another low-to-medium volume,open mold process
suitable for producing medium-to-large-sized parts.
➢ Greater shape complexity is possible with spray-up than with hand
lay-up.
➢ In the spray-up process, chopped fibers and resin are simultaneously
deposited on an open mold.
➢ Usually glass fiber rovings are used in this process.
➢ The glass fiber rovings are fed through a chopper and propelled into
the resin stream,which is directed to the mold.
➢ The spray gun consists of two nozzles:one nozzle sprays resin
premixed with catalyst or catalyst alone, while another nozzle sprays
resin premixed with accelerator.
➢ The resin mix pre-coats the strands of glass fiber,and the coated
fibers with the resin is sprayed on the mold in an even pattern by the
operator.

25
Spray-Up Process

[Link]

26
Features of Hand/spray process

[Link]

27
 Assignment
Have a look at 15 different parts of your choice. Try to identify
the functional and non functional surfaces and then decide
whether to use a open/close mould process

28