CHAPTER-2

MANUFACTURING PROCESSES
2.0 MANUFACTURING PROCESS
Manufacture of product consists of sapin! te "ateria# in te desi!ned product
!eo"etr$ and finisin! it in a usa%#e for"& Te "anufacture of co"posite products
differs fro" "anufacturin! 'it con(entiona# "ateria#s in tree 'a$s& First#$) te
"ateria# structure of co"posites is a#so created 'i#e te product is %ein! "ade 'ic
"eans) tere is a !reater responsi%i#it$ on te "anufacturer to ensure tat te ri!t
"ateria# structure as desi!ned "ust %e created durin! te process& Second#$) teir is a
ce"ica# reaction in(o#(ed in te processin! of ter"oset resins and tis cure "ust %e
co"p#ete& Fina##$) co"posites are cost#$ "ateria#s and terefore e(er$ effort is needed to
partia##$ offset tis i! cost %$ i"pro(ed producti(it$&
2.1 Different Stages:
Te tota# "anufacturin! process in a co"posite product "a*in! operation can %e
di(ided into tree sta!es
+i, Pre processin! sta!e
+ii, Processin! sta!e
+iii, Post processin! sta!e
2.1.1 Pre pr!essing
Te pre-processin! operations are re-uired to "a*e te "ateria#s) "aciner$ and "ou#ds
read$ for processin! to co""ence& Pre-processin! of "ateria# as an i"portant ro#e in
co"posite product "anufacture& Ha#f a do.en "ateria#s !o into te preparation of
co"posites and so"e ce"ica#s are added in s"a## -uantities) te "easure"ent of 'ic
"a$ ta*e #on! ti"e affectin! te production ti"e& If "ateria#s are "ade in a read$ to use
for" in teir ri!t proportions) it 'i## not on#$ sa(e ti"e) %ut a#so e#p to "aintain te
"ateria# proportion 'itin te finised product& In processes in 'ic suc co"poundin!
is not possi%#e) te resin "i/ 'it in!redients can %e "ade separate#$ and te
reinforce"ent fi%res can %e stitced in a read$ to use for"& Te conditionin! of "ateria#s
for a trou%#e free processin! 'it "ini"u" production c$c#e ti"e is te "a0or tas* of pre
processin! operations& 1ifferent processin! "etods re-uire te "ateria# preparation a#so
"ade different#$&Pre processin! in ter"osets can %e of four "a0or t$pes
+i, Preparation of fi%re for eas$ #a$-up and for su%se-uent curin! reactions&
+ii, Preparation of resin "i/ture for 'et #a$-up& Fi##ers) additi(es) pi!"ents)
cata#$sts) acce#erator etc& are added to te resin) "i/ed proper#$ and *ept read$
for 'et #a$-up 2 i"pre!nation&
+iii, Preparation of "ou#din! co"pounds& Mou#din! co"pounds are read$ to use
"i/tures of "ateria#s prepared for co"pression "ou#din!& Te ra' "ateria#s in
ri!t proportion are se#ected and co"pounded in a read$ to use for"&
+i(, Preparation of pre-i"pre!nated seets or si"p#$ prepre!s& Tese are read$ to use
"ateria#s "ade of epo/$ or peno#ic "atrices) 'ic are i"pre!nated on te
reinforce"ents& Tese prepre!s can %e cut to sape) stac* 'it proper fi%re
orientation and cure 'itin a "ou#d&
2.1.2 Pr!essing
Processin! is te actua# sta!e of "a*in! te product in proper !eo"etric for"& In
ter"oset PMC) it in(o#(es
+i, P#ace"ent of reinforce"ents 'it or 'itout resin i"pre!nation)
p#ace"ent of "ou#din! co"pounds or prepre!s in proper proportion) orientation
and pac*in!&
+ii, Sapin! te product confi!uration
+iii, Curin! te resin into a so#id "ateria#
+i(, Re#easin! te "ou#ded product fro" te "ou#d &
Te processin! "etod sa## ensure te fo##o'in! re-uire"ents3-
te "ateria# co"position and "icrostructure of te finised product sa## %e as per te
desi!n
te processin! operations inc#udin! te eat and pressure app#ied sa## not cause an$
de!radation of te fi%res) resins or fi##ers used
tere sa## not %e an$ ce"ica# reaction 'it te fi%re
easi#$ reproduci%#e
te processin! "etod sa## "aintain consistenc$ in te -ua#it$ of te product&
2.1." Pst pr!essing peratins
Te products re#eased fro" te "ou#d or "andre# as to %e su%0ected to (arious
operations to "a*e it a usefu# product& Ta%#e 2&4 su""arises te (arious post processin!
operations re-uired to "a*e a ter"oset PMC product to %e in a usa%#e condition
N Operatin Met#$ % P&rpse
4 5asin! 5it soap and 'ater to re"o(e re#ease a!ents
2 Cuttin! and tri""in! To re"o(e te f#as
6 Fi#in!) sandin! and
resin coatin! of cut
ed!es
Fi#in! and sandin! are done to "a*e te cut ed!es perfect#$ saped and
to re"o(e #oose "ateria#s& A## cut ed!es are coated 'it pi!"ented
resin and cured
7 Repairs if an$ Minor repairs #i*e !e# coat pee#in!) %#isters etc can %e repaired
8 1ri##in! o#es and
cuttin! openin!s
9o#t o#es are dri##ed and finised as in ite" 6 a%o(e& Openin! if an$ to
%e "ade can %e cut open and finised as in ite" 6
: ;oinin! 1ifferent parts can %e 0oined to!eter %$ o(er#a$ 'it FRP) %ondin!
'it adesi(es) ri(etin! or %o#tin!&
< Po#isin! Products 'it !e# coat finis can %e po#ised usin! po#isin! "ateria#s
#i*e 'a/po# and %uffin! 'ee#s
= PU coatin! 2 paintin! Products 'it or 'itout !e# coat can %e coated 'it po#$uretane
paint) or PU coatin! 'ic !i(es a !ood ard coatin!& Te process
in(o#(es app#$in! pri"er) putt$ and top coat& In te case of PU coatin!
te product can %e eated to "a*e te PU cure co"p#ete& Paintin!
re-uires a suita%#e pri"er to %e app#ied first and te paintin! done as in
oter cases of paintin!
Ta'(e 2.1 Pst Pr!essing Operatins
2.2 Manufacturin! Metods
Tere are 'e## o(er 22 "anufacturin! "etods for "a*in! ter"oset "atri/ co"posites&
Te$ can %e di(ided %road#$ into t'o !roups
+i, Metods suita%#e for custo"-%ui#t production& Man$ ce"ica# p#ant structures
are one-off ite"s "ade specia##$ to suit to te needs of tat particu#ar process of
te industr$& Se"i-auto"ated or fu##$ auto"ated "etods are not idea# for suc
indi(idua# structures& >er$ often site fa%rications are a#so re-uired for 'ic
"ecani.ed processes are not appropriate& Hand #a$-up) Spra$ up and (acuu"
infusion "etods are suita%#e for production of suc one-off ite"s&
+ii, Metods suita%#e for "ass production& Mecani.ed processes are idea# for
producin! co"ponents and structures in #ar!e nu"%ers& Pipes) Pipe fittin!s)
Structura# profi#es) !ratin!s) s"a## containers and pressure (esse#s can %e
produced in #ar!er nu"%ers usin! suc "etods& Resin Transfer Mou#din!
+RTM,) Co"pression "ou#din!) Fi#a"ent 5indin! and Pu#trusion are "etods
adopted for suc "anufacture&
Hand #a$ up) Spra$ up) resin transfer "ou#din! and fi#a"ent 'indin! are te four "a0or
fa%rication tecni-ues adopted for "a*in! ce"ica# e-uip"ent&
2.2.1 )an$ *a+,&p
Hand #a$-up is a #a%our intensi(e "etod of FRP fa%rication tat uses (er$ #itt#e capita#
intensi(e "aciner$& Te "ou#ds used can %e of 'ood) FRP or p#aster of Paris and te
"etod is 'e## suited for #o' (o#u"e production of #ar!er co"ponents& Since te
ce"ica# e-uip"ent is fair#$ #ar!e and custo"- %ui#t) and #a$ up "etod suits (er$ 'e##
for tis e-uip"ent&
)AND *A- UP
Pr!ess: Materia# #aid %$ and and %rus into te
"ou#d and conso#idated 'it a ro##er On#$
"a#e or fe"a#e "ou#d is used& Pressure not
essentia#& No precise contro# on resin content
and tic*ness& Mou#d can %e of FRP) 'ood)
p#aster of Paris or "eta#&
Fi'res Use$ an$ Fi're Cntent '+ .eig#t . A## fi%res can %e used . Copped strand
"at 6?-68@ . 5o(en ro(in! "at- 8?@ . 5o(en $arn c#ot- 8?@ . Unidirectiona#
c#ot :8 A <8 @
Resin s+ste/s &se$ an$ C&ring /et#$ . Po#$esters . (in$#esters . co#d set epo/ies .
Bi-uid peno#ics . Curin! is !enera##$ under a"%ient condition . Hot curin! can %e
done if "eta# "ou#d is used . Post curin! optiona# for po#$esters and essentia#
for (in$#esters) epo/ies and peno#ics .
Applications / Types of objects made . Large products. Low volume production. Only
one side finish. Used for automobiles, buildings, boats and ships, chemical
equipment and miscellaneous custom-built products
2.2.2 A&t!(a0e M&($ing
AUTOCLAVE MOULDIN After lay-up, the
product is cured in an autoclave. Vacuum, pressure
and temperature are applied. One male or female half
of mould made of F! or metals is used.
Fi'res Use$ an$ Fi're Cntent '+ .eig#t . 5o(en ro(in! "at :?-<?@ . 5o(en $arn
c#ot :?-<?@ . Unidirectiona# c#ot <?-=?@ . Mu#tia/ia##$ 'o(en or stitced te/ti#es .
Resin s+ste/ % C&ring . Epo/ies) po#$i"ides and peno#ics used in 'et #a$ up or prepre!
for" . Curin! can %e at a"%ient or e#e(ated te"perature . Under pressure .
App(i!atins % T+pes f '1e!ts /a$e . Hi!#$ stressed . Critica# co"ponents %ot "ade
2 #ar!e and s"a## in si.e . Aerospace and defence app#ication products .
2.2." Fi(a/ent .in$ing Met#$
In tis "etod) resin 'etted reinforce"ents are 'ound on a "andre# a#on! predeter"ined
directions& After 'indin! te re-uired tic*ness) te resin is cured and te product is
re#eased fro" te "ou#d& Te tecni-ue is used for "a*in! pressure (esse#s) pressure
%ott#es) oi# pipe #ines etc&
FI*AMENT .INDING )E*ICA*
Ra(in!s 'etted 'it resin or prepre!s ro(in!s or tapes are
'ound on a rotatin! "andre#& An!#e of 'indin! can
%e (aried
Fi'res Use$ an$ Fi're Cntent '+ .eig#t . Ro(in!s :? -<?@.
Resin s+ste/ % C&ring. Po#$ester and Epo/ies co#d cured or ot cured. Peno#ics and
furans ot cured.
App(i!atins % T+pes f '1e!ts /a$e. Suita%#e for c$#indrica# and a/is$""etric
o%0ects. Non-a/is$""etric profi#es can %e 'ound usin! co"puter contro##ed 'indin!
"acine. Pipes) e#icopter %#ades) ci"ne$s. Pressure (esse#s) roc*et "otor casin!s.
2." C&ring f !/psites
Transfor"ation of uncured or partia##$ cured fi%er-reinforced ter"osettin! po#$"ers
into co"posite parts or structures in(o#(es curin! te "ateria# at e#e(ated te"peratures
and pressures for a predeter"ined #en!t of ti"e&)ig# !&re te/perat&res are re-uired to
initiate and sustain te ce"ica# reaction tat transfor"s te uncured or partia##$ cured
"ateria# into a fu##$ cured so#id&)ig# !&re press&res are used to pro(ide te force
needed for te f#o' of te i!#$ (iscous fi%er-resin "i/ture in te "o#d)as 'e## as for
te conso#idation of indi(idua# indi(idua# un%ounded p#ies into a %onded #a"inate&Te
#en!t of ti"e re-uired to proper#$ cure a part is ca##ed te cure c$c#e&
2&6&4 Ge( Ti/e Test
Te curin! caracteristics of a resin-cata#$st co"%ination are fre-uent#$ deter"ined
%$ te !e# ti"e test& In tis standard test) a "easured a"ount +4?!, of a torou!#$ "i/ed
resin-cata#$st co"%ination is poured into a standard test tu%e& Te te"perature rise in te
"ateria# is "onitored as a function of ti"e %$ "eans of a ter"ocoup#e 'i#e te test
tu%e is suspended in a =2
?
C 'ater %at& A t$pica# te"perature-ti"e cur(e+a#so *no'n as
e/oter" cur(e, o%tained in a !e# ti"e test is so'n in fi!ure&2&4&Point-A) indicates te
ti"e re-uired for te resin Acata#$st "i/ture to attain te %at te"perature& Te initiation
of te curin! reaction at tis point is e(idenced %$ te %e!innin! of te te"perature rise&
As te curin! reaction %e!ins) te #i-uid "i/ %e!ins to transfor" into a !e#-#i*e "ass&
Heat !enerated %$ te e/oter"ic curin! reaction increases te "i/ te"perature) 'ic in
turn causes te cata#$st to deco"pose at a faster rate and te reaction to proceed at a
pro!ressi(e#$ increasin! speed& Since te rate of eat !eneration is i!er tan te rate of
eat #oss to te surroundin! "ediu") te te"perature rises rapid#$ to i! (a#ues& As te
curin! reaction nears co"p#etion) te rate of eat !eneration is reduced and a decrease in
te"perature fo##o's& Te e/oter"ic pea* te"perature o%ser(ed in a !e# ti"e test is a
function of te resin ce"istr$ +#e(e# of unsaturation, and te resin-cata#$st ratio& Te
s#ope of te e/oter" cur(e is a "easure of cure rate) 'ic depends pri"ari#$ on te
cata#$st reacti(it$& Sort#$ after te curin! reaction %e!ins at point A) te resin (iscosit$
increases (er$ rapid#$ o'in! to te increasin! nu"%er of cross-#in*s for"ed %$ te
curin! reaction& Te ti"e at 'ic a rapid increase in (iscosit$ ensues is ca##ed te !e#
ti"e and is indicated %$ te pint23 as so'n in fi! 2&4&Accordin! to one standard) te
ti"e at 'ic te e/oter" te"perature increases %$ 8&8
?
C a%o(e te %at te"perature is
considered te !e# ti"e& It is so"eti"es "easured %$ pro%in! te surface of te reactin!
"ass 'it a c#ean 'ooden app#icator stic* e(er$ 48 sec unti# te reactin! "ateria# no
#on!er aderes to te end of a c#ean stic*&
Fig&re.2.1 T+pi!a( te/perat&re,ti/e !&r0e 'taine$ in a ge(,ti/e test