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    This document discusses autoclave molding, which is a process that uses heat, pressure, and an inert gas to cure composites molded by open molding methods. The molded part is placed in a plastic bag under vacuum to remove air, and then heat and pressure are applied in an autoclave vessel to cure and densify the material. Autoclave curing produces consistent, homogeneous materials and is used for high-quality aerospace components, though it is a relatively expensive process.

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    Method 2

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    vani
    72 views16 pages
    This document discusses autoclave molding, which is a process that uses heat, pressure, and an inert gas to cure composites molded by open molding methods. The molded part is placed in a plastic bag under vacuum to remove air, and then heat and pressure are applied in an autoclave vessel to cure and densify the material. Autoclave curing produces consistent, homogeneous materials and is used for high-quality aerospace components, though it is a relatively expensive process.

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    This document discusses autoclave molding, which is a process that uses heat, pressure, and an inert gas to cure composites molded by open molding methods. The molded part is placed in a plastic bag under vacuum to remove air, and then heat and pressure are applied in an autoclave vessel to cure and densify the material. Autoclave curing produces consistent, homogeneous materials and is used for high-quality aerospace components, though it is a relatively expensive process.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    72 views16 pages

    Method 2

    Uploaded by

    vani
    This document discusses autoclave molding, which is a process that uses heat, pressure, and an inert gas to cure composites molded by open molding methods. The molded part is placed in a plastic bag under vacuum to remove air, and then heat and pressure are applied in an autoclave vessel to cure and densify the material. Autoclave curing produces consistent, homogeneous materials and is used for high-quality aerospace components, though it is a relatively expensive process.

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    © All Rights Reserved
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    Download as ppt, pdf, or txt
    of 16

    Autoclave moulding

    Autoclave Curing is a method in which a part, molded by one of the


    open molding methods, is cured by a subsequent application of
    vacuum, heat and inert gas pressure.
    The molded part is first placed into a plastic bag, from which air is
    exhausted by a vacuum pump. This operation removes air inclusions
    and volatile products from the molded part.
    Then heat and inert gas pressure are applied in the autoclave
    causing curing and densification of the material.
    Autoclave Curing enables fabrication of consistent homogeneous
    materials. The method is relatively expensive and is used for
    manufacturing high quality aerospace products.

    Autoclave moulding

    An autoclave is a closed vessel (round or cylindrical) in which


    processes occur under simultaneous application of high
    temperature and pressure.

    Autoclave
    An oven that allows for high pressures to be used.
    Composites cure under heat and pressure provides a superior part because
    the voids are reduced due to the pressure.
    Process
    The part is placed in the pressure vessel, and heated, pressure is applied
    simultaneously.
    Vacuum bagging can be used in an autoclave.
    Thermoset composites are crosslinked.
    Thermoplastics are melted.
    Advantages
    The pressure helps bond composite layers, and remove more voids in the
    matrix.
    Very large parts can be made with high fiber loadings.
    Properties are improved.
    Many different parts can be cured at the same time.
    Disadvantages
    Autoclaves are expensive
    Copyright Joseph Greene 2001
    3

    a)

    b)

    a) Autoclave process to make a laminated composite


    b) Prepregs of different orientations stacked to form a laminated composite
    Higher fiber volume fractions (60 65%) can be obtained

    Autoclave process- Charcteristics


    Very high quality product
    Generally prepregs are used
    Chopped fibres with resin can also be used
    Hybrid composites can be produced
    High fibre volume fractions can be obtained
    simultaneous application of high temperature and pressure helps in,
    * Consolidating the laminate.
    * Removing the entrapped air.
    * Curing the polymeric matrix.

    Injection moulding

    Injection Molding is a Closed Mold process in which molten polymer


    (commonly thermoplastic) mixed with very short reinforcing fibers
    (10-40%) is forced under high pressure into a mold cavity through an
    opening (sprue).
    Polymer-fiber mixture in form of pellets is fed into an Injection
    Molding machine through a hopper. The material is then conveyed
    forward by a feeding screw and forced into a split mold, filling its
    cavity through a feeding system with sprue gate and runners.
    Screw of injection molding machine is called reciprocating screw
    since it not only rotates but also moves forward and backward
    according to the steps of the molding cycle.
    It acts as a ram in the filling step when the molten polymer-fibers
    mixture is injected into the mold and then it retracts backward in the
    molding step.
    Heating elements, placed over the barrel, soften and melt the
    polymer.
    The mold is equipped with a cooling system providing controlled
    cooling and solidification of the material.

    Injection moulding

    The polymer is held in the mold until solidification and then the
    mold opens and the part is removed from the mold by ejector pins.
    Injection Molding is used mainly for thermoplastic matrices, but
    thermosetting matrices are also may be extruded. In this case
    curing (cross-linking) occurs during heating and melting of the
    material in the heated barrel.
    A principal scheme of an Injection Molding Machine is shown in the
    picture below.
    Injection Molding is highly productive method providing high
    accuracy and control of shape of the manufactured parts. The
    method is profitable in mass production of large number of identical
    parts.
    One of the disadvantages of the method is limited length of fibers
    decreasing their reinforcing effect.

    Injection moulding

    Injection moulding machine


    The injection molding machine comprises of:

    The plasticating and injection unit: The major tasks of the


    plasticating unit are to melt the polymer, to accumulate the melt in
    the screw chamber, to inject the melt into the cavity and to maintain
    the holding pressure during cooling.

    The clamping unit: Its role is to open and close the mold, and hold
    the mold tightly to avoid flash during the filling and holding.
    Clamping can be mechanical or hydraulic.

    The mold cavity: The mold is the central point in an injection


    molding machine. Each mold can contain multiple cavities. It
    distributes polymer melt into and throughout the cavities, shapes
    the part, cools the melt and ejects the finished product.

    The Injection Mold


    The mold consists
    Sprue and runner
    system
    Gate

    Mold cavity

    Cooling system

    (for thermoplastics)
    Ejector system

    Features of injection molding

    Direct path from molding compound to finished product


    Process can be fully automated
    High productivity & quality

    Injection molding machine

    Injection Molding Machine

    INJECTION MOLDING

    Thermoplastics : Polystyrene,PE, PP, ABC, PC,PMMA etc

    SHEET MOLDING COMPOUND (SMC)

    automated, continuous flow process


    resin paste (resin, filler, initiator, mold release and
    thickening agents) properly proportioned and mixed
    uniformly metered onto lower plastic (polyethylene,
    nylon) film
    reinforcement is placed onto lower plastic film
    top plastic film is coated in a similar manner with resin
    paste
    top plastic film feeds into moving belt to form
    continuous sandwich of fiber/resin
    compacted under controlled pressure
    taken up on rolls (2 ft - 5 ft width)

    DIFFERENT FORMS OF SMC

    random chopped (0.5 in - 2 in) fibers (SMC-R)


    continuous unidirectional fibers (SMC-C)
    combination of above (SMC-C/R)
    thickness varies between 0.25 in - 0.5 in
    thick molding compound (TMC) available in
    thicknesses up to 2 in

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