FABRICATION TECHNIQUES

 HAND LAYUP
 There are numerous methods for fabricating composite components. Some methods have
been borrowed (injection molding, for example). Selection of a method for a particular part,
therefore, will depend on the materials, the part design and end-use or application. The most
basic fabrication method for thermoset composites is HAND LAYUP, which typically
consists of laying dry fabric layers, or “plies,” or prepreg plies, by hand onto a tool to form a
laminate stack. Resin is applied to the dry plies after layup is complete (e.g., by means of
resin infusion).
 Hand layup, a common method for thermoset composites, involves manually layering dry
fabrics in a mold, followed by resin application, often through infusion. Curing can be at
room temperature or accelerated with heat and pressure, with autoclaves being used for high-
performance parts. Electron-beam, X-ray, and microwave curing are alternatives, each with
specific applications. UV curing, triggered by UV radiation, demands light-permeable
materials. Autoclaves, with computer control, efficiently cure multiple parts simultaneously.
Each method offers unique advantages and considerations in composite fabrication.

 Hand layup is a manual process used in composite manufacturing. Here's a detailed breakdown:
 Mold Preparation: A mold, typically made of fiberglass or metal, is prepared to represent the
final shape of the desired composite part.
 Release Agent Application: To facilitate the removal of the finished part, a release agent is
often applied to the mold surface.
 Reinforcement Material Placement: Layers of reinforcement material, such as fiberglass
mat or woven carbon fiber fabric, are manually placed into the mold. These materials provide
strength and stiffness to the final composite.
 Resin Application: Liquid resin, often a two-part epoxy or polyester resin, is applied by hand
to saturate the reinforcement layers. This can be done using brushes or rollers, ensuring
thorough wetting of the fibers.
 Consolidation: To remove air bubbles and ensure good contact between the resin and
reinforcement, workers use tools like rollers or squeegees to consolidate the layers.
 Repeating the Process: Additional layers of reinforcement and resin may be added,
depending on the design requirements and desired properties of the final composite.
 Curing: The composite is left to cure, allowing the resin to harden and bond with the
reinforcement materials. The curing time depends on the type of resin used.
 Demolding: Once cured, the finished part is demolded, revealing the final shape. Excess
material is trimmed, and finishing processes may be applied.
Hand layup is a versatile method suitable for small to medium production runs, offering
flexibility in design and material choices. While it may not be as automated as some modern
techniques, it remains widely used for its simplicity and cost-effectiveness in producing various
composite components.
 vacuum infusion
 In vacuum infusion fabrication, the process begins with a mold that represents the final
shape of the desired composite part. Dry reinforcement materials, often fiberglass or
carbon fiber fabrics, are strategically laid into the mold.
 Once the fibers are in place, a vacuum bag is sealed over the mold, and a vacuum pump is
used to evacuate the air from the space between the mold and the bag. This creates a
negative pressure environment, compressing the dry fibers and removing any trapped air.
 Next, liquid resin is introduced into the mold. The vacuum pressure helps the resin to
infiltrate the dry fibers, ensuring a thorough and even distribution. This is a critical step
for creating strong, lightweight composite parts with minimal voids.
 After the resin infusion is complete, the composite is allowed to cure, forming a solid and
durable material. Vacuum infusion is favored for its ability to produce high-quality,
consistent parts with excellent strength-to-weight ratios. It's a widely used technique in
advanced manufacturing processes.

 Open molding
 Open contact molding in one-sided molds is a cost-effective and widely used process for
manufacturing fiberglass composite products, commonly applied to boat hulls, RV
components, truck parts, and large noncomplex shapes like spa tubs and shower stalls.
 This method involves hand layup or a semi-automated spray-up technique. In the spray-
up process, a mold is treated with release, and catalyzed resin and glass fiber are
simultaneously sprayed into the mold using a chopper gun.
 To minimize volatile organic compounds (VOCs), non-atomizing spray guns are used.
Vacuum-Assisted Resin Transfer Molding (VARTM) is another technique where resin is
drawn into a preform through a vacuum, eliminating the need for high heat or pressure.
 VARTM is cost-effective, suitable for large, complex parts, and has been utilized by
industry giants like Boeing and NASA for aerospace-quality laminates without the need
for an autoclave.

 High-volume molding methods

 Compression molding, a high-volume thermoset process, utilizes durable metal dies,
ideal for quantities exceeding 10,000 parts. It employs sheet molding compound (SMC),
a composite sheet with chopped fiberglass between resin layers, producing up to 200,000
parts with forged steel dies. Low-pressure SMC formulations offer cost-effective closed-
mold processing with low VOC emissions.
 Automakers explore carbon fiber-reinforced SMC for its strength-to-weight ratio.
Injection molding, a fast and low-pressure closed process, is increasingly using bulk
molding compounds (BMC), gaining traction in markets like automotive. Filament
winding, pultrusion, and tube rolling are continuous fabrication methods with
applications in golf clubs, pipes, and cylindrical parts.
  Automated fiber placement (AFP) and automated tape laying (ATL) offer high-speed and
precise material placement for large thermoset parts. Centrifugal casting provides an
alternative to filament winding for pipes with enhanced strength.
 Extrusion is utilized for fiber-reinforced thermoplastic components, particularly wood-
plastic composites used in decking, siding, and fencing, marking a significant market
growth in the past decade.

 The fabrication technique for Fiber-Reinforced Polymers (FRPs) reinforced with

graphite carbon nitride (GCN) would depend on various factors, including the specific
properties desired in the final material and the characteristics of graphite carbon nitride.
While the exact technique might vary based on the research or industry standards, here
are some general steps that could be involved:

1.Material Preparation: Mix the polymer matrix (e.g., epoxy resin) with appropriate curing
agents and additives to form a liquid mixture.

2.Graphite Carbon Nitride Treatment: Depending on the nature of graphite carbon nitride, it
might undergo a specific treatment or modification to enhance its compatibility with the polymer
matrix and improve adhesion to the fibers.

3.Fiber Impregnation: Infuse the reinforcing fibers (likely carbon fibers) with the prepared
polymer matrix, ensuring thorough impregnation of graphite carbon nitride. This can be achieved
through techniques like hand lay-up, filament winding, or automated methods.

4.Layering and Orientation: Arrange the impregnated fibers in specific layers and orientations
to achieve the desired mechanical properties. The arrangement may be optimized for aeronautical
applications, considering factors like strength and weight.

5.Molding: Place the layered composite into a mold that represents the final shape of the
component. This can be a complex process to ensure that the fibers are aligned correctly.
6.Curing: Subject the composite to a curing process to initiate the polymerization of the resin.
This step is crucial for forming a solid and strong structure. The curing temperature and duration
would depend on the specific resin system used.

7.Post-Curing: Some FRP composites undergo post-curing to further enhance their mechanical
properties and ensure complete polymerization.
8.Quality Control and Testing: Conduct thorough quality control checks to ensure the
fabricated material meets the desired specifications.

9.Mechanical Testing: Perform mechanical testing on the fabricated FRP composite to evaluate
its properties. This may include tests for tensile strength, flexural strength, impact resistance, and
other relevant mechanical characteristics.