Manufacturing Processes for Advanced Composites book cover

Manufacturing Processes for Advanced Composites

• One of very few books available to cover this subject area.
• A practical book with a wealth of detail.

This book covers the major manufacturing processes for polymer matrix composites with an emphasis on continuous fibre-reinforced composites. It covers the major fabrication processes in detail.

Very few books cover the details of fabrication and assembly processes for composites. This book is intended for the engineer who wants to learn more about composite processing: any one with some experience in composites should be able to read it. The author, who has 34 years experience in the aerospace industry, has intentionally left out mathematical models for processes so the book will be readable by the general engineer.

It differs from other books on composites manufacturing in focussing almost solely on manufacturing processes, while not attempting to cover materials, test methods, mechanical properties and other areas of composites.

Audience
Materials engineers; manufacturing engineers; design engineers; structural engineers; mechanical and chemical engineers; production supervisors and consultants.

Hardbound, 532 Pages

Published: December 2003

Imprint: Elsevier

ISBN: 978-1-85617-415-2

Contents

  • Chapter 1 - Introduction to Composite Materials and Processes
    Laminates
    Fibers
    Matrices
    Product Forms
    Overview of Fabrication Processes
    Advantages and Disadvantages of Composites
    Applications
    Summary
    Acknowledgement
    References

    Chapter 2 - Fibers and Reinforcements
    Fiber Terminology
    Glass Fibers
    Aramid Fibers
    Ultra-High Molecular Weight Polyethylene (UHMWPE) Fibers
    Carbon and Graphite Fibers
    Woven Fabrics
    Reinforced Mats
    Chopped Fibers
    Prepreg Manufacturing
    Summary
    References

    Chapter 3 - Thermoset Resins
    Thermosets
    Polyester Resins
    Epoxy Resins
    Bismaleimide Resins
    Cyanate Ester Resins
    Polyimide Resins
    Phenolic Resins
    Toughening Approaches
    Physiochemical Characterization and Quality Control
    Chemical Testing
    Rheological Testing
    Thermal Analysis
    Glass Transition Temperature
    Summary
    References

    Chapter 4 - Cure Tooling
    General Considerations
    Thermal Management
    Tool Fabrication
    Summary
    References

    Chapter 5 - Ply Collation
    Prepreg Control
    Tool Preparation
    Manual LayUp
    Ply Collation
    Flat Ply Collation and Vacuum Forming
    Automated Tape Laying
    Filament Winding
    Fiber Placement
    Vacuum Bagging
    Summary
    References

    Chapter 6 - Curing
    Cure of Epoxy Composites
    Theory of Void Formation
    Hydrostatic Resin Pressure Studies
    Chemical Composition Variables
    Net and Low Flow Resin Systems
    Resin and Prepreg Variables
    LayUp Variables
    Debulking Operations
    Caul Plates and Pressure Intensifiers
    Condensation Curing Systems
    Residual Curing Stresses
    Exotherm
    In-Process Cure Monitoring
    Cure Modeling
    Summary
    References

    Chapter 7 - The Interaction of Chemical Composition and Processing on Laminate Quality
    Prepreg Physical Properties
    Chemical Properties
    Thermal Properties
    Rheological Properties
    Laminate Evaluations
    Summary
    References

    Chapter 8 - Adhesive Bonding and Integrally Cocured Structures
    Adhesive Bonding
    Advantages of Adhesive Bonding
    Disadvantages of Adhesive Bonding
    Theory of Adhesion
    Joint Design
    Adhesive Testing
    Surface Preparation
    Epoxy Adhesives
    Bonding Procedures
    Sandwich Structures
    Honeycomb Core
    Honeycomb Processing
    Balsa Wood
    Foam Cores
    Syntactic Core
    Inspection
    Integrally Cocured Structure
    Summary
    References

    Chapter 9 - Liquid Molding
    Preform Technology
    Fibers
    Woven Fabrics
    Three-Dimensional Woven Fabrics
    Knitted Fabrics
    Stitching
    Braiding
    P4A Process
    Random Mat
    Preform Advantages
    Preform Disadvantages
    Integral Structures Made by Textile Processes
    Preform Lay-Up
    Resin Injection
    Curing
    RTM Tooling
    Resin Transfer Molding Defects
    Resin Film Infusion
    Vacuum Assisted Resin Transfer Molding
    Summary
    References

    Chapter 10 - Thermoplastic Composites
    The Case for Thermoplastic Composites
    Thermoplastic Composite Matrices
    Product Forms
    Consolidation
    Thermoforming
    Joining
    Summary
    References

    Chapter 11 - Commercial Processes
    Lay-Up Processes
    Compression Molding
    Injection Molding
    Structural Reaction Injection Molding
    Pultrusion
    Summary
    References

    Chapter 12 - Assembly
    Trimming and Machining Operations
    General Assembly Considerations
    Hole Drilling
    Fastener Installation
    Sealing
    Painting
    Summary
    References

    Chapter 13 - Nondestructive Inspection and Repair
    Nondestructive Inspection
    Visual Inspection
    Ultrasonic Inspection
    Portable Equipment
    Radiographic Inspection
    Thermographic Inspection
    Repair
    Fill Repairs
    Injection Repairs
    Bolted Repairs
    Bonded Repairs
    Summary
    References

    Appendix A - Metric Conversions

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