Manufacturing Processes for Advanced Composites

Manufacturing Processes for Advanced Composites

1st Edition - December 18, 2003

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  • Editor: Flake Campbell Jr
  • Hardcover ISBN: 9781856174152
  • eBook ISBN: 9780080510989

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Description

• 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.

Readership

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

Table of 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

Product details

  • No. of pages: 532
  • Language: English
  • Copyright: © Elsevier Science 2003
  • Published: December 18, 2003
  • Imprint: Elsevier Science
  • Hardcover ISBN: 9781856174152
  • eBook ISBN: 9780080510989

About the Editor

Flake Campbell Jr

Affiliations and Expertise

Senior Technical Fellow at the Boeing Phantom Works in Missouri, USA.

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