Design and manufacture of structural composites /

Design and Manufacture of Structural Composites provides an overview of the main manufacturing challenges encountered when processing fibre-reinforced composite materials. Composites are unique in that the material is created at the same time as the structure, forming a very close link between the c...

Full description

Bibliographic Details
Corporate Author:	ScienceDirect (Online service)
Other Authors:	Harper, Lee (Editor), Clifford, Mike (Editor)
Format:	eBook
Language:	English
Published:	Cambridge, MA : Woodhead Publishing, an imprint of Elsevier, 2023.
Edition:	First edition.
Series:	Woodhead Publishing series in composites science and engineering.
Subjects:	Fibrous composites. Manufacturing processes. Composites à fibres. Fabrication. fibrous composite. manufacturing. Fibrous composites Manufacturing processes Compostos fibrosos. Fabricació. Electronic books. Llibres electrònics.
Online Access:	Connect to the full text of this electronic book

Table of Contents:

Intro
Design and Manufacture of Structural Composites
Copyright
Dedication
Contents
Contributors
Preface
Section A: Introduction to composite materials
Chapter 1: Introduction
1.1. What is a composite?
1.2. Composites manufacturing
1.3. Where is the industry heading?
1.3.1. Automation
1.3.2. Sustainability
1.3.3. Challenges
1.3.3.1. Aerospace
1.3.3.2. Renewable energy
1.3.3.3. Energy storage
1.3.3.4. Automotive
1.4. Summary
References
Chapter 2: Reinforcing fibres
2.1. Introduction
2.2. Types of fibre reinforcement
2.2.1. Inorganic fibres
2.2.1.1. Glass fibre
2.2.1.2. Basalt fibre
2.2.1.3. Ceramic fibres
2.2.2. Organic fibres
2.2.2.1. Carbon (graphitic) fibre
2.2.2.2. Aramid fibre
2.2.2.3. Natural (cellulosic) fibres
2.2.2.4. Other polymer fibres
2.3. Fibre coatings
2.4. Fibre forms, nomenclature, properties, and testing
2.4.1. Finished fibre forms
2.4.2. Textile materials
2.4.3. Discontinuous fabrics
2.4.4. Properties and testing
2.5. Sustainability, recycling, and reuse
2.6. Summary
References
Chapter 3: Resins for structural composites
3.1. Introduction
3.2. Thermosetting resins
3.2.1. Epoxy
3.2.1.1. Epoxy chemical structures
3.2.1.2. Epoxy cure mechanism
3.2.1.3. Epoxy curing agent selection
3.2.1.4. Epoxy resin selection
3.2.1.5. Bio-derived epoxies
3.2.1.6. Recyclable epoxies
3.2.1.7. Powder epoxy
3.2.2. Unsaturated polyester
3.2.3. Vinyl ester
3.2.4. Benzoxazine
3.2.5. Bismaleimide
3.2.6. Toughened thermosets
3.3. Thermoplastic resin systems
3.3.1. PEEK and PEKK
3.3.1.1. Chemical structure
3.3.1.2. Crystallisation and morphology
3.3.2. Anionic polyamide 6 (APA6)
3.3.3. Liquid acrylic resins
3.4. Resin characterisation
3.4.1. Rheometry.
3.4.2. Differential scanning calorimetry
3.4.3. Dynamic mechanical analysis
3.5. Property comparison of resins
3.6. Summary
Acknowledgements
References
Chapter 4: Intermediate composite materials
4.1. Introduction
4.2. Dry intermediate materials
4.2.1. Dry fibre architectures
4.2.2. Tow handling and spreading
4.2.3. Continuous fibre architectures
4.2.3.1. Woven textiles
4.2.3.2. Non-crimp fabrics
4.2.3.3. 3D fabrics
4.2.4. Discontinuous fibres architectures
4.2.4.1. Unifilo/chopped strand mat
4.3. Thermoset matrix composite intermediates
4.3.1. Preimpregnated reinforcements
4.3.2. Thermoset prepreg manufacturing process
4.3.3. Thermoset moulding compound manufacturing process
4.3.4. Recent developments in thermoset prepregs
4.4. Thermoplastic matrix composite intermediates
4.4.1. Thermoplastic matrix classes and final applications
4.4.2. Tape thermoplastic matrix intermediates
4.4.3. Comingled fibre thermoplastic matrix intermediates
4.4.4. Powder thermoplastic matrix intermediates
4.5. Cores
References
Section B: Material preforming and conversion
Chapter 5: Two-dimensional to three-dimensional dry fibre preforming
5.1. Introduction
5.2. Fabric materials for preforming
5.2.1. Choice of commercial fabrics
5.2.2. Formability mechanisms
5.2.2.1. In-plane shear
5.2.2.2. In-plane tension
5.2.2.3. Out-of-plane bending
5.2.2.4. Material sliding
5.3. Fabric forming techniques
5.3.1. Press tool forming
5.3.2. Diaphragm forming
5.3.2.1. Single vs double diaphragm forming
5.3.3. Forming-induced defects
5.3.3.1. Press tool forming defects
5.3.3.2. Diaphragm forming defects
5.4. Scenarios for defect mitigation
5.5. Summary
References
Chapter 6: Automated fibre placement
6.1. Introduction.
6.1.1. History and development of the automated tape laying and automated fibre placement processes
6.1.2. Current status of processes
6.1.3. Basic principles of operation, gantry versus robot designs
6.1.4. Thermoset matrix processing
6.1.5. Thermoplastic matrix processing
6.2. Current challenges
6.2.1. Productivity issues
6.2.2. Accuracy and control issues
6.2.3. Temperature control and heating strategies
6.2.4. Lay-up head design and operational issues
6.2.5. Impacts on cured ply thickness and as-laid quality
6.2.6. Monitoring and control
6.3. Next-generation AFP/ATL
6.3.1. Advantages and limitations of AFP and ATL
6.3.2. Steering effects and tack
6.3.3. Dry fibre AFP issues
6.3.4. Tailored blanks and post-forming
6.4. Development areas and future research
References
Chapter 7: Braiding and filament winding
7.1. Introduction
7.2. Braiding
7.2.1. 2D braiding
7.2.2. 3D braiding
7.2.3. Braid parameters
7.2.3.1. Braid angle
7.2.3.2. Cover factor
7.2.3.3. Interlacement pattern
7.2.3.4. Nesting factor
7.2.3.5. Fibre tension
7.2.4. Braid design tools
7.2.5. Braid manufacturing challenges
7.3. Filament winding
7.3.1. Conventional filament winding
7.3.2. Multifilament winding
7.3.2.1. Multi-supply filament winding (MFW)
7.3.2.2. 3D filament winding (3DFW)
7.3.2.3. Multifilament winding with through-thickness reinforcement
7.3.3. Toroidal winding
7.3.4. Filament winding challenges
7.4. Hybrid braid-winding
7.5. Structural performance of braided and filament-wound composites
7.5.1. Braiding
7.5.2. Filament winding
7.5.3. Braid-winding
7.6. Summary
References
Chapter 8: Three-dimensional woven composites
8.1. Introduction
8.2. Definition, classification, and motivation of 3D woven preforms
8.2.1. Definition.
8.2.2. Classification of 3D woven preforms
8.2.3. Motivation for 3D woven preforms
8.3. Manufacturing of 3D woven preforms
8.4. Influence of microstructural parameters on defects in 3D woven composites
8.5. Performance and failure mechanisms of 3D woven composites
8.5.1. Tensile performance
8.5.2. Compressive performance
8.5.3. Impact performance
8.6. Machine developments for 3D woven composites
8.7. Summary
References
Section C: Moulding
Chapter 9: Autoclave and out-of-autoclave processing of prepregs
9.1. Introduction
9.2. Prepreg processing
9.2.1. Consumables
9.3. Curing equipment and tooling
9.4. Prepreg materials
9.4.1. Prepreg fibre bed properties
9.4.1.1. Fibre bed compaction
9.4.1.2. Fibre bed permeability
9.4.1.3. Air permeability
9.4.1.4. Prepreg bulk factor
9.4.1.5. Prepreg degree of impregnation
9.4.2. Prepreg resin properties
9.4.2.1. Prepreg cure kinetics
9.4.2.2. Prepreg rheological behaviour
9.4.2.3. Volumetric changes
9.4.2.4. Resin elastic modulus
9.5. Process design
9.5.1. Air evacuation
9.5.2. Cure cycle selection
9.6. Challenges
9.6.1. Sandwich panels
9.6.2. Complex shaped parts
9.7. Summary
References
Chapter 10: Liquid composite moulding
10.1. Introduction
10.2. Theory
10.2.1. Process cycle
10.2.2. Resin flow
10.2.3. Resin cure
10.2.4. Heat transfer
10.2.5. Inter-dependencies
10.2.6. Solution for the resin flow problem
10.3. Processing properties of reinforcement
10.3.1. Reinforcement types
10.3.2. Permeability
10.3.2.1. Basics of permeability
10.3.2.2. General comments on permeability
10.3.2.3. Practical problems
10.3.3. Compaction response
10.4. Processing properties of matrix
10.4.1. Thermoset matrix
10.4.2. Thermoplastic matrix
10.5. Implementation.
10.5.1. Practical considerations
10.5.2. Process variants
10.5.2.1. Resin transfer moulding
10.5.2.2. High-pressure resin transfer moulding
10.5.2.3. Vacuum infusion
10.5.2.4. Light RTM
10.5.2.5. Compression RTM
10.5.3. Sandwich structures
10.6. Summary
References
Chapter 11: Compression moulding
11.1. Introduction
11.2. Overview of compression moulded composite materials and their associated processing routes
11.2.1. Sheet moulding compounds (SMCs)
11.2.1.1. Constituents
11.2.1.2. Fabrication of SMCs
11.2.1.3. SMC compression moulding process
11.2.2. Glass mat thermoplastics (GMTs)
11.2.2.1. Constituents
11.2.2.2. Fabrication of GMTs
11.2.2.3. GMT compression moulding process
11.2.3. Long fibre thermoplastics (LFTs)
11.2.4. Platelet and scrap materials
11.3. Compression moulding challenges
11.3.1. Consolidation and flow phenomena during compression moulding
11.3.2. Flow-induced fibre microstructures
11.3.3. Flow-induced pore evolution during compression moulding
11.4. Current trends and outlook
References
Chapter 12: Thermoplastic stamp forming
12.1. Thermoplastic forming processes and process windows
12.2. Materials and deformation mechanisms
12.3. Material characterisation
12.4. Process modelling and sensitivity analysis
12.5. Forming-induced defects
12.6. Design for manufacturing
12.7. Current industrial practice
Acknowledgments
References
Chapter 13: Composite injection overmoulding
13.1. Injection moulding process
13.2. Composite injection overmoulding-Background
13.3. Composite injection overmoulding process
13.3.1. Single-stage injection overmoulding
13.3.2. Two-stage composite injection overmoulding
13.4. Material characteristics
13.4.1. Material compatibility.