Manufacturing Processes for Advanced Composites - 1st Edition - ISBN: 9781856174152, 9780080510989

Manufacturing Processes for Advanced Composites

1st Edition

Editors: Flake Campbell Jr
eBook ISBN: 9780080510989
Hardcover ISBN: 9781856174152
Imprint: Elsevier Science
Published Date: 18th December 2003
Page Count: 532
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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

Details

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

About the Editor

Flake Campbell Jr

Affiliations and Expertise

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