Manufacturing

Vacuum Bagging
BTG Composites Inc. 2010 1
2.5m Steel Mould for End Dome
End Dome Laminate Being Laid
Up and Wet Out
y CSM and WR glass
laminate laid up in
mould in layers
y GP resin fully
saturates laminate
y Rollers used to work
out air entrapment
y Allowed to gel
C‐veil and CSM Layers Added
With VE Corrosion Resin
y VE resin and
CSM/C‐veil added
after GP resin
system gels
y Final layers are
critical to the
corrosion
protection
End Dome Section Prior to Trim
End Dome Trimmed to Fit
Inside FW Main Tank
y End dome cut to fit
inside 2.5m UST
cylinder
y Edge is trimmed
y Inside and outside
edges are sanded for
bonding
View of End Dome in UST
y End dome is fit into
UST
y Dome held in place
with wooden peg
or wire in drill hole
y Exterior bond uses
catalyzed resin and
roving on exterior
seams
Interior of Domes Bonded
(Vinyl Ester Resin)
y Catalyzed resin roving
forced into interior
seams
y Eight (8) CSM layers are
built up covering the
bond interface across
the dome and cylinder
section
y Two (2) C‐veil layers
finalize section
CSM Layers Added Next ‐ Then
CSM With GP Resin
Cured Manway Marked for Final
Trim to Fit Dimensions
Manufacturing Methods
y Spray‐up
y Fibers are chopped, coated with resin and sprayed onto the
mold
Mylar Film Provides UST Release on
Steel Winding Mandrel
y 250 mm Mylar film
wound onto rigid
mandrel length
y Film overlapped at
least 4 inches or 100
mm
y Prevents composite
resin sticking to steel
mandrel when curing
in place
Initial Start of C‐veil Surface
Tissue Onto Wet Mandrel
y Light resin spray of
VE resin on Mylar
covering on mandrel
y Manual installation
of C‐veil surface
tissue starts the
process
Tissue Comes in 250mm to
1000mm Widths
y Team installs the
surface tissue onto
the mandrel
y Mandrel rotates
slowly as team lays
up C‐veil
y Overlaps are about
4 inches or 100 mm
Overall View of Corrosion Resin Wet
Out With Spraying
250mm CSM Layer Number #1
Wound Onto C‐veil
y First of two (2) CSM
layers hand wound
on C‐veil
y Single roving strand
holds CSM layer
tight to the mandrel
y About 1 inch or
25mm overlaps
CSM Starts to Absorb Resin
y First CSM layer begins to
absorb VE resin from C‐veil
layers
y Two men required for this
operation:
y CSM material deposition
y Roving strand tie‐down
y Resin spray required later
Second CSM Layer Added and
Resin Sprayed Onto Layers
y Second layer of CSM
added
y VE resin sprayed onto
both layers of CSM
y With mandrel
rotating, resin is
worked into layers:
y Spraying continues
y Roller wetout (right)
y Hand Lay‐up (wet and prepreg)
Wet
Prepreg
Various Bagging/Lay‐up Methods
y Hand Lay‐up (wet and prepreg)
Lay-up
Prepreg Wet Resin
Wet Lay‐Up Process
Placement of Dry Reinforcement
Build Up Required Thickness
Resin Impregnation Part Cure
Traditional Lay‐Up and Autoclave Cure
Automated Ply Cutting
Ply Collation
Autoclave Curing Cured Laminate

48‐Inch Wide Carbon/Epoxy Broadgoods
Carbon Fabric Prepreg With Backing Paper
Typical Hand Collation of Carbon/Epoxy Part
Typical Hand Collation of Carbon/Epoxy Part
Vacuum Bagging
y Provides for increased part consolidation
y Reduces matched die mold costs
Caul Plate Above the Bleeder Pack
Nylon Vacuum Bag
Breather Material
Caul Plate
Inner Bag
Bleeder Material
Porous Release Material
Composite Lay-Up
Double Sided Tape
Double Sided
Tool
Tape
Dam
Caul Plate Within the Bleeder Pack
Nylon Vacuum Bag
Breather Material
Inner Bag
Partial Bleeder Material
Perforated Caul Plate
Partial Bleeder Material
Porous Release Material
Composite Lay-Up Double Sided Tape
Tool Double Sided

Dam Tape
Bagging Schematic for No Bleed Resin System
Nylon Vacuum Bag
Breather Material
Caul Plate
Inner Bag
Composite Lay-Up
Double Sided Tape
Tool Double Sided

Dam Tape
Part Bagged with Nylon Film
Large Reusable Silicone Rubber Vacuum Bag
Satellite Composite Lay‐up
y Embedded Heatpipe Panel
BTG Composites Inc. 2009
Modern Autoclave System
Gas Flow Velocity Turbulence Near Door
Loading Large Wing Skin for Autoclave
Production Batching Using Racks
Another problem that can be encountered is blockage (large parts

can block the flow of gas to smaller parts located behind them)
Manufacturers typically use large racks to ensure even heat flow and
maximize number of parts that can be loaded for cure
Potential Bagging Problems
Kobe, Japan – 1995 Earthquake
Carbon Fibre Sheet Application
Increase
2
(1,000m )
1250
1200
Area sheet applied/year
1050
1000 1000 1000
900
750
500
250
200
30 60
0
1993 1994 1995 1996 1997 1998 1999 2000
Year
Carbon Fibre Sheet Prepreg
Sheet Used for Tunnel Retrofit
Summary
y Wet lay‐up and prepreg lay‐up are similar
y But vacuum bagging and hand lay‐up are “labor
intensive”
y Also limited to nominal size parts
y Need automation to increase lay‐down rates
y Traditional “aerospace” process – particularly with very
exotic satellite and space systems
Pultrusion as Manufacturing
Method
y Pultrusion
y High volume production method
y Typical continuous speed (2‐4 ft/min rate)
y Sometimes higher with innovation
y Comparable to extrusion but the main processing force is
tension
y Generally “constant cross‐section” structures
y Profile is pulled from the machine
y Primarily commercial, but … not necessarily …
Typical Pultrusion Components
Gathering, Consolidating Fibres
y Dry fibres must be
“collected” and aligned
y Fibres collected in variety
of steps and stages
y Each stage “consolidates”
fibre pack
y Then – fibres enter the
resin bath to be wet out
y Carbon hard than glass
(smaller diameter fibre =
more surface area)
Dry Fibres Collected from Creel
Additional Material (“Mat”)
Added Along w/Fibres
Resin Injection Directly Into Die
(Alternate to Normal Resin Bath)
More Typical Wet Resin Bath
More Messy ???
Heated Die Design – Where
Cure Happens !
What Happens Within Die ???
y Die forms the final geometric shape
y Usually there are several heated die zones
y Each has increasing temperature range
y Structure must almost completely cure within die
y Final die zone may be a “post‐cure” region
y Exit region designed to “cool” down
y Possible problems:
y Poor temperature control
y “Sloughing” of outer resin materials
y Inadequate through‐thickness curing
y Cure gradient – should be “uniform” at all times
“Pullers” Move Part Along …
Cut‐off Saw Cuts to Part Length
Pultruded Grating
Corrosion Resistant Decking
is Very Common
Rods, Channels, Bars, Cylinders …
Thermoplastic Pultrusion
y Raw Materials (More Options Over Thermosets)
y Powder resin
y Commingled fibres
y Liquid resin
y Prepreg
y Similar Overall Process
y Fibers (or Prepreg) paid off creel
y Resin can be added by powder or hot melt/liquid method
y Pultrusion then formed into the desired shape/profile under
pressure
y Composite frozen (cooled) and solidified
y Profile can then be rolled onto a core or cut into discreet
sections
Thermoplastic Pultrusion
y Advantages:
y Low cost continuous process
y Low labor costs
y High volume manufacturing
y Simple process
y Good quality consistent profiles/shapes
y Limitations:
y Needs large run sizes to minimize cost
y Amortize tooling & setup costs
y Limited to simple shapes (typical)
y Rods, beams, ellipses, etc.
y Limited fiber directionality (typical)
y UD fibers, fabrics
y Limited time at temperature & pressure
y Can limit strength between plies
Typical Thermoplastic Applications
CF/PEEK
Profile Shapes
Courtesy SR Taylor Assoc.
TP Composite TP Composite
Profile Shapes Profile Shapes
Courtesy Gurit Suprem Courtesy Phoenixx TPC
CF/PPS
Guitar Necks
Courtesy graphiteMOSES
Advanced Composite Tube
y Critical straightness
alignment needed
y 40‐ft (12.2 m) length
with only 0.02‐in
(0.5 mm) deviation
y Most critical:
y Die alignment
y Puller alignment
y Balanced loads on
part (all positions)
y No differential
heating profiles
Puller Clamping Forces Critical
Radial Forces Very High on Tube
FEA Model Simulates Loading
y Tube profile modeled
to simulate puller
clamping loads
y Loads believed to be
failing tube (cracking
heard during pulling)
y Axi‐symmetric loads
causing cracking of
“hot” tubes
“Hot” Tube Loaded Unevenly
Utility Poles
Structural Beams
Bridge Structures, Decks
Bridges Major Contributions
Gathering Reinforcements
Straight Infrastructure Profiles
Gathering Dry Materials ‐‐
Innovation
Unique “Snap” Joint Concept
Assembly of “Snap” Lock Joints
“Snap” Lock Joint Part
“Snap” Lock Type Truss Beam
Center Core for Transmission Line
y Steel center core y CF/glass center core
y Heavyweight y Lightest weight
y Considerable line sag y Virtually no line sag
y Low temperature limit y Much higher temperature
Fire Barriers Between Transformer
y Transformers need fire
barriers between
y Fires can destroy
complete power complex
y Composite pultrusion has
many advantages:
y Fire resistant materials
y Simple pultruded parts
y Low cost fabrication
y Rapid installation
y Corrosion resistant
Summary
y Pultrusion is a continuous process
y Used with both thermosets and thermoplastics
y Constant cross‐section structures
y Curved structures possible
y Often employed in commercial products; numerous civil
infrastructural applications
y Typical resins are thermosets:
y Polyesters
y Vinyl esters
y Epoxies
y Phenolics
FW Carbon Fiber
Pressure Vessel
Contour Tape Layup Machines (CLTM)
Contour Tape Layup
Machines (CLTMs) had
two major drivers:
y The interest in weight
savings
y The need to use CF
composites on stealthy
military aircraft
y The development of
contour tape layup
machines was
instrumental in reducing
costs
Layup tool for large wing skin

positioned under CLTM gantry
Winding Axes of Motion
(Filament Winding and Fiber Placement)
Axis Motion
1 Mandrel rotation
2 Longitudinal carriage
travel
3 Radial travel
4 Head/wrist ‐ vertical
5 Head/wrist ‐ roll
6 Head/wrist ‐ pitch
7 Head/wrist ‐ yaw
Winding Axes of Motion
y Axes 1 and 2 (mandrel rotation and carriage travel) ‐‐‐ like a
lathe:
y Not Export controlled
y Pipe, Tubes, Cylinders, Constant cross‐section, etc.
y Axes 3 (radial) and 4 (vertical) ‐‐‐ typical add‐on:
y Tapered parts, Variable cross‐section, etc.
y Axes 5 (roll), 6 (pitch) and 7 (yaw) ‐‐‐ add‐ons for more
complex parts (pressure vessels with domes)
y Reasons for “add‐on” axes 3 thru 7:
y More efficient composite compaction
y More efficient process (shorter “turn‐around” region)
y Lays fiber band down more precisely
y Lays fiber band “flat” onto shaped surface
y Minimizes fiber path “slippage”
y Typically required for high performance, optimized structures
The Rules and Reality
y If the part is round and symmetrical – it
can be wound
y It does not need to be round to be wound!
y Requires innovation and ingenuity
y Process may be slower
y May require “hybrid” processes
Filament Winding vs. Fiber Placement
FILAMENT WINDING
AUTOMATED FIBER PLACEMENT
y Wet winding or prepreg
y Prepreg only
y Various tow/roving forms
y Slit tape or narrow tows
y Tension on fibers
y No tension on fibers
y Tow/roving not cut
y “Tow‐cut; tow‐add” on each
y Large number of tows/rovings
y 20‐32 tow/roving limit is typical
possible
y Fiber direction can be changed
y Fiber path cannot be “steered”
y Compaction by “tacking” to
y Compaction from winding process
surface (normal roller)
and fiber tension
y High performance products
y Very cost effective process
y Fiber “lay‐down” rate in 2‐25 lbs
y Rapid “lay‐down” possible (50‐
per hour range
1000 lbs per hour)
y Mostly aerospace market – only
y Aerospace, commercial, industrial
30+ machines worldwide
market segments
Ceiling View of Helical Wind
70‐Degree Helical Layers
y FW USTs depend
upon good 3‐layer
winding at
70‐degree angle
y Resin bath must be
maintained at
correct level
y Do not use old resin
in bath too long
Top View of UST With Ribs
Interior View of UST Ribs & Wall
y Minimum wall
thickness in UST
is 7.3 mm
y Rib thickness is
17.0 mm
minimum
y April 1995 and
May 1996 tests
provided first test
data
Trimmed UST Main Body
Launch Tube (Forward Segment)
y 96 in. diameter
y 35 ft. length
y Taper steel mandrel
(0.001 in./ft.)
y AS4/HBRF‐55A/3501‐6
y S‐2/HBRF‐55A external
machine surface (joints)
y Oven cured with prepreg
postcure for stress relief
AMROC Rocket Motor Case
y AMROC composite case for
hybrid rocket motor
y Carbon fiber/epoxy wet
winding
y Internal insulator material:
y Kevlar/phenolic resin
y Wet wind process
y Ablation properties
improvement
y Fwd/aft dome sections
pictured (co‐wind)
AMROC Insulation
y Kevlar/phenolic
insulation system
y Continuous fiber
insulation system
y High performance
resistance to char
y Successfully
demonstrated in
firings
Filament Wound Overwrap
y Hydraulic Aircraft
Actuator System
y High modulus, high
strength carbon fiber
y Hoop wrap and axial
stiffening for aircraft
actuator
y Lighter weight
y Higher performance
Low Angle Fibers
y Low angle fiber
placement (15°)
possible
y Resin bath (wet) wetout
on moving delivery
system (box)
y Rapid fiber laydown
rates (to 1,000 lb/hr)
y Source: EnTec
Multiple Spindle Winding
Composite Ice Auger Sections
y Filament wound
tubular ice augers
y Carbon fiber winding
materials
y Epoxy resin for high
performance
y Wound‐in helical
auger “threads”
Conformable Tank ‐ “Triple”
y Carbon/Epoxy tank design
y AS4 and IM7 grade carbon
fibers
y Foam used to fill interstitial
areas
y Hoop overwrap increases
structural performance
y CNG/NGV applications
y Design and analysis
challenge
Flight Simulator and Amusement Ride
y Filament Wound/
Contact Molded
Composite
y 16 passenger ride
y Combined motion:
y360° at 70 RPM
y Vertical motion
y Horizontal motion
y Pitch up/pitch down
y 0.25 to 3.0 g’s
y E‐glass/vinyl ester
y Stitch‐bonded fabrics and
polyurethane core
Composite Flight Simulator Ride in Motion
y Upside down
y 12° pitch up
y Rotating at 70 RPM
y Top‐most (vertical)
position
y NASA Orlando, FL
(USA) Space Camp
Modified XXsys Robo Wrapper
II
y Improved version of
initial Robo Wrapper
system
y Carbon fiber towpregs
y Hoop wrap constraint
Typical Prepreg Applications
Hydrogen Tanks for fuel
cell cars
FW Prepreg “Translation”
Carbon Fiber Pressure Vessel Performance 5.75 in. Diameter (14.64 cm)
Mfg Certified TCR Delivered

Fibre Manufacturer Fibre Strength Fibre Strength Translation
Fibre
(ksi) (ksi) (%)
Toray T1000GB 12K-40D 911 845 93
Toray M30SC 18K-50C 823 780 95
Toray M30GC 18K-11E 739 655 89
Toray T700SC 12K-50C 720 685 95
Toho G30-700 12K 689 628 91
Grafil 34-700 12K 646 534 85
Thornel T300C 12K 500 448 90
Mitsubishi TRH-50 12K 735 654 89
Mitsubishi TR-50S 12K 683 583 85
Controlled Epoxy Resin Content
Prepregs Wet Winding
Resin content can be specified Operators must adjust “doctor

by customer blade” on resin bath
Resin content can be controlled Use visual inspections during
to ±2% winding process
Verified by weighing Consistent resin content is
sample lengths received difficult to maintain with many
from suppliers spindles and large resin baths
All cylinders on multi-spindle Cylinders on different
winder receive the same resin spindles often have
content different resin contents
Resin Content Accuracy – Prepreg Winding
Prepreg Fiber Path
• The tack from

the prepreg
allows the
winding head
to follow the
exact path as
designed ---
that means
“little slippage”
Filament Winding Main Cylinder
Body (Thick‐wall Structure)
Fiber Band Width
A good fibre delivery path
eliminates gaps between fibers
Achieved though good alignment

from the creel to the delivery
head
Pot Life Issues
Prepreg has a “pot life” from 3 Wet wind resin has pot life of 6-8
months to 1 year at room hours
temperature – 75ºF
Excess epoxy resin must be
Retesting of materials essentially cured and discarded at the end
not necessary of each day
Little or no wasted materials for As building temperature changes
resin advancement during the day, viscosity also
changes
Winter vs. summer blends etc.
Performance Comparisons for
High-Pressure Cylinders
Coefficient of Variation (CV) Winding operators require many

controlled to 2.0% to 3.0% hours of training to be able to
control resin contents
Burst strengths and
pressure cycle testing much Difficult to produce consistent
more consistent burst tests and pressure cycles
Allows for lower pressure Designs take into account high
design parameters variability
Wet-Winding
Advantages Disadvantages
Initial low raw material Requires resin mixing

cost
Requires resin baths
Simple raw material Resin pot-life issues
storage: cold box not
generally required Solvents needed for
cleanup
Allows flexibility in
Material waste
fibre / resin combinations
Potential health hazards
Cantilevered
Pipe, 90‐deg Elbow System
Dual‐Winding System
Large Diameter FW System
In‐Line Dual Winder
Pipe Winder
Polar Winding Machine
Multiple Spindle Winding
Low Angle (10‐15°) Pipe Wind
Low Angle Fibres
y Low angle fibre
placement (10‐15°)
possible
y Resin bath (wet) wet‐
out on moving delivery
system (box)
y Rapid fibre lay‐down
rates (to 1,000 lb/hr)
Pressure Tests w/Axial Load
(United Arab Emirates)
y Bench test to high
pressures
y Axial load due to
confined fixture
y Tests to 120 bar
y Short segment FRP
pipe units
Large FW Buried Pipe Structures
Composite (Glass/Epoxy) Drill Pipe
`Short Radius’ Drill Pipe
Missile Launch Tube
y Aft Segment
y 96 inch diameter
y S‐2/HBRF‐55A glass
surface (joints) machined
for tolerance control
y 20 ft. lengths
y Thick‐wall structure
y Tapered joint section
Launch Tube (forward segment)
y 96 in. diameter
y 35 ft. length
y Taper steel mandrel
(0.001 in./ft.)
y AS4/HBRF‐55A/3501‐6
y S‐2/HBRF‐55A external
machine surface (joints)
y Oven cured with prepreg
post‐cure for stress relief
Shuttle Booster FWC (Launch Vehicles)
Requires Joint Prepreg Reinforcement Materials
AS4/3501‐6 prepreg
Provides 0°/90° strength
enhancement for joint
Requires additional 350°F
post‐cure cycle
Reduces internal residual
stresses
Broadgoods interspersed
within winding patterns
Void contents — 3‐10%
Composite Tanks
1990
NASP,
1995 1998
Lobed X-33, Lobed
DC-XA
NGLT
2001 Reusable
X-34 Pathfinder NGLT Composite
Conformal Composite
Decades of technical development provide a strong

technology base for launch vehicle development.
Waste Water Tanks
(Commercial Aircraft)
y Filament wound
carbon fibre/epoxy
y Airbus A‐330
commercial aircraft
application
y Manufactured by
MAN Technologies
Pressure Vessel Failure
(Long Haul Trucking)
y E‐glass fibres/epoxy resin
y Filament wound over
HDPE plastic liner
y 2:1 ellipse dome
y Designed for 120 psig
with 5.0 safety factor
y Inadequate design:
Based on metal technology
Stress ratio of 1:0
Poor transition region
design
AMROC Insulation
y Kevlar/phenolic
insulation system
y Continuous
fibereinsulation
system
y High performance
resistance to char
y Successfully
demonstrated in
firings
AMROC Rocket Motor Case
y AMROC composite case for
hybrid rocket motor
y Carbon fibre/epoxy wet
winding
y Internal insulator material:
Kevlar/phenolic resin
Wet wind process
Ablation properties
improvement
y Fwd/aft dome sections
pictured (co‐wind)
Side View of Helical UST Winding
Ceiling View of Helical Wind
70‐Degree Helical Layers
y FW USTs depend
upon good 3‐layer
winding at
70‐degree angle
y Resin bath must be
maintained at
correct level
y Do not use old resin
in bath too long
Hoop Buckling Ribs Important
for Burial Loads
y Buckling ribs are high
compaction, high fibre
volume stiffeners
y Ribs are eventually co‐
cured with UST main
cylinder body
y 500 mm spacing
y 19 hoop wraps
y 60‐roving count
Top View of UST With Ribs
Interior View of UST Ribs & Wall
y Minimum wall
thickness in UST
is 7.3 mm
y Rib thickness is
17.0 mm
minimum
y April 1995 and
May 1996 tests
provided first test
data
Trimmed UST Main Body
Completed JFI Hi‐Kleen UST (Underground
Storage Tank) in Malaysia (Petronas Gas)
UST Backfilled With “Beach Sand”
(UL Certification Testing)
y Restrained UST is
backfilled using
“beach sand”
y Manway metal cover
and rubber gasket
installed first
y Sand covers UST to
1.0‐1.5m depth
Industrial ‐‐‐ Paper Rollers
(US and UK Companies)
y Cost savings and
increased composites
performance
y Fatigue and damping
improvements
y Replacement market
upgrades
Orthogonally‐Stiffened Pressure Vessel
y Orthogonal isogrid design
pattern
y Isogrid wound over internal
tooling first
y Pressure vessel skin structure
wound over isogrid
Internal Isogrid and Stiffening Rings
y Filament Wound Cylinder
y Triangular Isogrid pattern
y Circumferential stiffening rings
(hoop wrapped pattern)
y Carbon/epoxy skin structure
overwrap
Design Comparison:
Composite vs. Metallic Drive Shaft
y Composites allow one
piece construction
due to high natural
frequency
y high stiffness
y low weight
y Elimination of joint
results in cost savings
Carbon Fiber Drive Shafts
y Carbon fiber (with
some S‐2 glass fibre)
and epoxy
y Drive shafts with metal
end fittings
y High performance
torque requirement
y Rugged field
environment
Filament Wound Overwrap
y Hydraulic Aircraft
Actuator System
High modulus, high
strength carbon fibre
Hoop wrap and axial
stiffening for aircraft
actuator
Lighter weight
Higher performance
Spherical Pressure Vessel
y Spherical pressure vessel
y Tapered filament wound
skirt
y Co‐cured system
y High performance
structure
High Performance Centrifuges
y Carbon/epoxy filament
wound centrifuge
y Higher fibre strength
translation required (>93%)
y Fibre strength and stiffness
critical to success
Composite Ice Auger Sections
y Filament wound
tubular ice augers
y Carbon fibre winding
materials
y Epoxy resin for high
performance
y Wound‐in helical
auger “threads”
FW “Bearing” Rings with Various Internal
Fittings
Door “Spring” Mandrel
FW Unidirectional Springs (Aircraft)
Compression Spring
y Glass fibre and epoxy
y Filament wound spring
y All fibres are unidirectional
within the winding path
y Fibre content ~ 65% volume
y Stiffness controlled by fibre
type (glass, carbon) and
volume %
Carbon Fiber: Wind Turbine Applications
(Blades, Supports)
Dry Kevlar/EPDM Rubber “Resin”
Production Line for Manufacture of
„Liners“ Low Pressure Vessels
Flame Treatment Of Liners
FW – Machine w/2 X 5 Spindles
Producing Alternate Tanks
Secondary Winding
of Multiple Tanks
Curing FW Vessels in the Oven
Further
Transportation
Along
Production
Line
FINISHED PRODUCT:
Pressure Vessel
for the Storage of
Liquid Gas
CF Materials Have Real Potential
y CFRP Materials have an opportunity to enable new,
lower cost, deepwater field solutions
y Barriers to entry however are real – but unlike other
industries are not directly commercial
Composite OIL & GAS Products
Accumulator bottles Risers (drill & production)
High Pressure Energy Storage
(Accumulators)
y Offshore accumulators for
TLP tensioning systems
y Mature product line (Sole
source for composite
accumulators)
y Multiple customers,
ASME or NGV2
certification required
Composite Pressure Vessels for Tensioning System
10 3/4” Composite Production Riser
(Instrumented with fibre optics ‐ Tested to 12,000 psi)
Composite Steel
Air Weight, (lb/ft) 28 65
Water Weight (lb/ft) 13 55

Cost ($/ft) 325-350 200 - 315
“Trapped Joint” End Fitting
Composite Drilling Riser
Current Composite Riser Production
y Non‐automated production
y One week production time per joint
Field Installation of Composite Drilling Riser
Composite Spool for Multi-Flow Meter
FATIGUE TESTING OF HEIDRUN RISER
>160,000 cycles (required: 140,000 cycles)
Tube Trailer Applications
Installation in a bulk hauling
application
Transportation of Natural Gas
y Pipeline
y By ship as liquefied
natural gas (LNG)
y By ship as compressed
natural gas (CNG)
Spoolable Tubing
Spoolable Tubing
Why Carbon Fibre Composite
Pressure Vessels ?
y Syntactic foam limit is typically around 750‐1000 m
depths (expensive on site costs)
y Steel pressure vessels heavy, corrosion‐prone, and
trade‐offs show non‐competitive
y Carbon fibre filament wound pressure vessels optimum
for 1000‐4000 m depths
Submerged Pressure Vessels Provide
Submerged Line Support
Filament Winding Approaches
y Monocoque vs. dual cylinder main body sandwich
design
y Monocoque main body with “iso‐grid” or “ortho‐grid”
stiffening structure
y Dome geometries (numerous configurations and
thickness scaling available)
y Dome‐to‐cylinder joint technique and bonding/sealing
method
y Wet‐winding vs. towpreg winding
Externally Loaded Pressure Vessels Pose
Design & Manufacturing Issue
y Key design challenges:
y Buckling loads
y Low compression strength
y Long‐term creep
y Water‐tightness and moisture uptake
y Key manufacturing needs:
y Maintain very low void content
y Maintain fibre straightness (no waviness)
y No gaps, laps and minimize fibre bridging
y Desire high fiber volume fraction (>60%)
Void Content Improvements – Increase
in Compression Strength !
High Void Content Low Void Content
Dome Winding with T700‐12K
Towpreg Epoxy Material
View of End Dome Winding
View of Double Dome Helicals
View of Hoop Windings
Dual Dome Winding Segments
Filament Wound Dome Section
Assembly of Domes to Main Cylinder Section
Large (1‐2m) Diameter, Thick‐wall (30‐75mm)
CF Pressure Vessels – 2000m Depth
Fully Assembled Pressure Vessel
(~ 1m Diameter)
Automated Fiber Placement
(AFP)
ADC
AFP “Head” Characteristics
Typical Fiber Placement Head
Typical 7-axis AFP
Machine
Showing 90° & 45°

laminate buildup
Small fixed width fiber

package with paper
backing (on back of
individual tows or slit
tape) – so it does not
“stick” in storage spool !
AFP Head Characteristics at Lay‐down
Point for Thermoplastic Materials
AFP Prepreg “Tows” Can Be
Directed Uniquely
y Prepreg tow or slit tape materials may be deposited onto
the mandrel “uniquely”:
y Up to 32 individual tows or tape are laid down
y Each one may be cut at any time,
y Each one may be added back into the process at any time,
y There is no “pulling” force on these tows !
y Only a slight normal surface compaction
y Hence scrap rate is very low !!!
Example of Tow “Cut” and “Add”
AFP Tows and Slit Tape
Can be “Steered”
y While FW “pulls” on continuous fiber tows or rovings, AFP
does not
y FP can change direction (called “steering”) within the
layer up to 20‐30 degrees
y Fiber path better lines up with localized loads instead of
“average” load directions
AFP Actually “Steers” Fiber Paths
AFP Composites Simplify and Speed
Manufacturing (Boeing 787)
One Piece Barrel Section
(Boeing 787)
One Piece Barrel (Nose) Section
(Boeing 787)
Automated Fiber Placement
Bell Helicopter
y Bell Helicopter pioneered use
of fiber placement development of Civil Tiltrotor
the V‐22 Osprey Tiltrotor.
V‐22 fiber placed components
include:
Fuselage Side Skins
Sponsons
Main Landing Gear Doors
Drag Angles
The AFP parts are produced on
Boeing’s Large AFP system in
Philadelphia. PA
Fiber placement of V-22 aft fuselage
V‐22 Aft Section Fiber Placement
Fiber Placement with Towpreg
Towpreg Placement Machine
Towpreg CF Placement Machine
With Glass Fibre
Ring Winder
Fiber Placement (Tape Laydown)
Tapered, Constant Thickness AFP Shell
(Carbon/Epoxy)
Fiber Placement Operation
AFP of Aircraft Duct Shape
Complex AFP Duct Section
AFP of Aircraft Duct Section
View of AFP Head During Winding
F‐22 Inlet Duct
Raytheon Premier 1
AFP Aircraft Engine Parts (Blue)
AFP Carbon Tow/Epoxy Isogrid Shell
AFP Isogrid “Crossover” Points
Close‐up of “Crossover” Points
AFP of Aircraft Stabilizer Section
Thermoplastic Composites Can Be
Made More Economical
y Use of automated work‐cells
y An In‐situ process Is used
y Prepreg tape is “heated on the fly” (keeps ‘moving’)
y Melted tape is consolidated to the substrate
y Heating, cooling sequence of events critical
y Part is built up one strip at a time
y Traditional TP resins offer wide range of opportunities
Composite Pressure Vessel
Small Tapered Duct Via AFP
AFP Oil & Gas Applications
AFP Oil & Gas, Marine Applications
AFP TP Composites
Thermoplastic Tail‐boom
Fiber Placement of Thermoplastic
Composites
A380 Aft Pressure
Bulkhead
Plastic “Liquid Molding” Processes
Led to RTM & VARTM Methods
y Several “liquid moulding’ processes were background to
conventional RTM/VARTM:
– RIM ‐‐‐ Reaction Injection Molding (and) Resin Injection
Molding (NO fibre)
– RRIM ‐‐‐ `reinforced’ RIM (Fibre added)
– SRIM ‐‐‐ `structural’ RIM (MORE fibre added)
y Urethane resin technology (1940‐1950) added technology
y RTM and VARTM processes grew from various aspects of
these technologies
Resin Infusion Patent History
y RTM – a grew out of urethane technology developed
under the Marco patents in the 1940‐1950 time
period (pressure feed)
y VARTM – grew out of combining “vacuum bag”
technology in various 1960‐present patent versions
(vacuum infusion)
– RFI – grew out of McDonnell Douglas work in 1980’s
patents (vacuum infusion, separated materials/resin sheets)
– SCRIMP ™ – grew out of Seemann’s patents in 1980’s and
early 1990’s (vacuum infusion, flow media)
Major Developments – Last 15+ Years
(Closed Mold, Markets)
y Lots of new infusion resins – PE, VE, Epoxies
y More than existed in the early‐mid 1980’s
y Excellent high temperature resins (BMI, CE, PI)
y “Heavy areal weight” reinforcement materials
y Various process options (>30+)
y Available “flow media” materials (because of SCRIMP)
y Core materials with induced flow porosity (z‐direction flow)
y High performance, complex structural preforms:
y Higher fibre volume fractions
y Z‐direction reinforcements
y Complex geometries
Typical Resin Systems
Resin Family Process Temperature (F) Main Industry
Polyester Ambient – 100 Commercial
Vinyl Ester Ambient - 180 Commercial
Phenolic 140-200 Commercial
Epoxy 180-350 Commercial/Aerospace
Toughened Epoxy 250-350 Aerospace
Cyanate Ester 250-350 Aerospace
Bismaleimide 350-500 Aerospace
Polyimide 350-700 Aerospace
Phenylethynyl
Terminated Imides >350 Aerospace
(PETI)
Composite Process Comparisons
Fibre Volume Range
Process Raw Material Form(s)
(%)
Injection Molding 15-30 Liquid resin, short fibres
Liquid resin, fibre

Compression Molding 35-45
reinforcements
RTM/VARTM (RFI, Liquid resin, resin film,
40-70
SCRIMP, etc.) complex preforms
Prepreg resin/fibre
Vacuum Bagging 55-65
materials
Liquid resin with variety
Pultrusion 50-75
of continuous fibres
Wet winding or towpreg
Filament Winding 50-65
continuous fibres
Prepreg resin/fibre
Fibre Placement 55-65
materials in tows
Traditional Cost Breakdown in RTM or
VARTM Process
Process Aspect Contributing Amount
Tooling 15-20%
Process Equipment 10-15%
Materials ~10%
Preform Lay-up in
35-40%
Tooling
Miscellaneous Labor ~20%
Processing Pressure Level
Aspects
y Commercial RTM/VARTM utilize pressures on order of 30‐
50 psi
Mold pressures not usually increased after injection
y Aerospace processing occurs initially at low pressure, but
then …
After infusion the pressure is increased to 100‐500 psi (0.7‐
3.5 MPa) level within mold
RTM and VARTM Characteristics
y Both are `low’ pressure processes typically
y Infusion pressures usually <100 psi
y Industry typically uses 30‐50 psi
y Vacuum levels run as high as possible
y Low viscosity resins highly desirable
y Viscosity between 10‐800 centipoise common
y Large variety of resin families available
Example Liquid Viscosities
Liquid Viscosity (cps)
Water 1
Kerosene 10
Antifreeze 15
10 Wt Motor Oil 50‐100
30 Wt Motor Oil 150
Castor Oil 1000‐2000
40 Wt Motor Oil 1000‐2000
Honey 2000‐3000
Chocolate Syrup 10,000‐25,000
Ketchup/Mustard 50,000‐70,000
Resin Temperature vs. Viscosity
Epoxy – Temperature Effects
PE/VE – Temperature Effects
Resin Viscosity vs. Temperature
No ! Short Cycle
Longer Cycle
Mold Fill Time Affected by Resin
Viscosity and Temperature
y Epoxy resin viscosity,
process temperature
affects mold fill time
y Injection pressure
dependence:
– 76‐80F effect is strong up
to 40 psi only
– 110‐120F effect is not
pressure dependent
Temperature Has Strongest Effect
on Cycle Time
y Epoxy resin viscosity
strongly affected by
temperature
y Mold fill time above 120F
NOT temperature
dependent
y Mold fill time 10X slower
at 60‐65F than 120F and
above
Preform `Permeability’ Strong
Function of Fiber Volume
y Low `permeability’
exists at very high fiber
volumes (>50%)
y High `permeability’ is Good
best for preform wet
out though:
Poor
– Lower fiber volumes
– Faster, easier wet out
– Shorter cycle times
– But, lower mechanical
properties (structural)
RTM/VARTM Processes Have
Numerous Variations Today
y Automotive industry utilizes RTM/VARTM liquid molding
(LM) processes
y Other common versions (about 40‐50):
– VARTM, VARI, VRTM, VIMP, VIP, VIM – vacuum methods
– TERTM, RARTM, CERTM – internal expansion materials
– CIRTM, MIRTM – various injection/infusion methods
– RLI, RFI – liquid and film resin systems
– SCRIMP, UVRTM – flow media and UV systems
– CARTM, RTM LITE – flow media variations
– ETC …..
Resin Transfer Molding (RTM)
y Resin – pressure fed into closed mold
y Mold consists of two or more rigid sections
y Excellent dimensional control for part
y Often heated tools (steel, aluminum, Invar)
y Aerospace structures preference
y Pressures upwards of 500 psig (3.45 MPa)
y Higher fibre volumes (>55‐65% Vf)
RTM Processing Steps
Conventional RTM Process (PRESSURE)
y Two resin components
metered according to
vendor mix ratios
y Pumped by pressure
feed through mixing
head
y Static mixer injects resin
into closed mold
y Resin wets out the
preform contained
within mold
Earliest (1989) RTM Airfoil
Structural Parts
y AS4 and IM7 type carbon
fiber preforms
y Carbon fabric and braided
preforms demonstrated
y Hexcel HBRF‐315 toughened
resin formulation
y Aerodynamic control
surfaces for missile wings
y Molded‐in fittings, closed or
open ends, and internal
support structures
Combination of Materials in RTM Blade
y ATR‐72 propeller blade
y Braided carbon and Aramid
materials utilized
y One‐part epoxy resin
y Aramid provides impact
toughness
y Smooth aerodynamic
surfaces
Complex Composite Blade
y Made by RTM process
Woven carbon fabric
Braided glass preform
Internal polyurethane foam
core
Integral carbon fibre spars
Nickel strip leading edge
y 55% fiber volume
y Source: Dowty Aerospace
Resin Infusion Parts on Aircraft
“4‐Pack” RTM Fan Exit Case
y AS4‐12K carbon fibre
materials
y One‐part high
temperature epoxy
resin
y “4‐pack” sections are
sub‐assemblies of fan
exit case
y Complex structure
using RTM process
F‐119 Fan Exit Composite Structure
(RTM)
Fan Inlet Case Structure for
Military Engine
Aircraft Engine Stator Vanes (High
Temperature Epoxy or Better)
175-315C (350-600F)
or Better Resin Capability
High Temperature Braided
Composite Valves
Applications
Automotive & Transport
Applications
Marine
High Performance Marine
Large Sailing Vessels (e.g. Mirabella - 100m Mast)

Lightweight superstructures
Increased stiffness/fatigue performance
Military Stealth Vessels
High Performance Racing Bicycle
Wheels w/Hub Inserts
y RTM process used for
racing bicycle wheels
y Carbon fibre preforms
y Epoxy resin RTM
processing
y Internal foam core
y Molded‐in fittings
Braid Used Extensively in RTM for
Sports and Recreation Purposes
y Carbon fibre 2D
braided preforms
y High performance
bicycle swing arm:
Primary braided legs
Cross‐over part (over
thermoplastic hollow
core)
y RTM resin infusion
(DOW Tactix 123)
y Low viscosity resin
Vacuum‐Assisted RTM (VARTM)
y Resin – pulled in by vacuum (negative
pressure)
y Rigid tool on one side only
y Flexible, bagging materials on outside
y Tool surface control on one side only
y No additional pressure added later
y Fibre volumes more like 45‐55% Vf
y SCRIMP™ actually a subset within VARTM
VARTM Processing Steps
VARTM Process Components
y Closed mold
y Structural preform
y Resin system
y Pressure pot or resin
source containment
vessel
y Injection port (s)
y Vacuum port (s)
y Resin collection pot
Square Plate, VARTM Process
Demonstration (Lab Size)
y Top mold section also
simple:
y Welded angle iron
y Plexiglas plate (safety)
y Glass can shatter
y C‐clamps used for mold
closure
y Chopped strand mat
used in demonstration
y Ready for resin infusion !
Resin and Catalyst Premixed:
Then Degassed Under Vacuum
y Resin pressure pots
used to contain source
resin
y Resin/catalyst mixed
and stirred
y Vacuum degassed
prior to infusion (15
minutes)
y Vacuum typically in 15‐
29 inch Hg range
Initial Resin Flow Into CSM
Preform (at 15 sec)
y Process parameters:
y 25‐inch Hg vacuum
y Room temperature
y Polyester (GP) resin
y CSM material
y Bottom resin infusion
flow pattern circular:
y CSM random fiber
y No set orientation
y Symmetric flow
y Vacuum /pressure pots
CSM Shows Symmetrical Resin
Flow & Wetout (at 30 sec)
y CSM random fiber
attributed to circular
flow pattern
y Resin flow rapid:
y Low fiber content
y Low viscosity resin
y Good vacuum draw
y No mold leaks
y Simple geometry
Resin Flow at Roughly 75 sec
y Uniform resin flow
pattern
y Has not yet reached
boundaries within
mold
Resin Flow Reaches Seals at
Roughly 100‐105 sec
y Resin edges meet
seals
y No resin leakage
y Only corner areas left
to wet‐out
y Vacuum locations in
corners now obvious
y Process nearing
completion
Complete CSM Preform Wetout
at 150 sec
y Resin wet‐out
completed (145‐sec)
y Upper left corner
slightly lagging
y Student business cards
can be seen on lower
side of mold
y Polyester/CSM part
cures in 40 minutes
VARTM Road Bike Frame Structure
y Carbon/epoxy RTM
process
y Lightweight and
modern design
features
y Monocoque frame,
forks, chain‐stay
y Complex structure fits
RTM process
Bicycle Swingarm Comparisons
y RTM composite bicycle
swingarm (bottom)
y Conventional aluminum
swingarm (top)
y RTM part has molded‐in
fittings
y Reduced part count and
machining operations
y Cosmetic fabric design
features
VARTM Multiple Port Injection
Minesweeper Rudder
Completed Fan Cowl Door
Large Wind Energy Blade
Manufacture (VARTM)
Foam Core Material in Kits Prior
to Resin Infusion
Resin Infusion Products Can Be
Extremely Large in Size
Transport of a LM 38.8 m rotor blade
SCRIMP™ Process
y Developed, patented by Bill Seemann (1980’s)
y Applicable primarily to large surface areal parts
y Incorporates two major features:
y Lateral surface resin distribution via open tubes,
y Porous “flow media” in form of netting or screen
materials
y Most efficient for nominal thicknesses in range of 0.5‐ to
4‐inch (12‐100 mm) typically
y Fibre volumes often in 45‐55% Vf
SCRIMP Processing Steps
SCRIMP™ Setup for Marine Structures
y Basic SCRIMP™ process (Seemann’s Composite Resin Infusion
Molding Process):
One‐side tooling
Preform structure
Resin source and vacuum source
SCRIMP™ vacuum bag and “medium”
SCRIMP™ Requires Vacuum Bag Integrity
y Vacuum bag and
“medium” integrity
critical
y Resin infuses rapidly
through “medium”
distribution channel
y Resin next spreads out
horizontally
y Infusion migrates
through preform
thickness
SCRIMP™ Infuses 64‐ft Yacht Hull
y SCRIMP™ process used on
large area products
y Nine (9) injection regions
processed at same time
y Resin infused from large
catalyzed resin drums
y Process allows rapid preform
infusion
y No interface “knitting”
problems observed
Flow Media Placed Topside
Flow Media Placed Mid‐Plane
Right Side (Top Fiberglass); Left Side (Bottom Fiberglass
Plus Flow Media)
Stringers in Place; Covered by Fiberglass
and EnkaFusion™ Flow Media
Resin Ports Installed and Attached to Flow
Media Incorporated Into Preform Stringers
As Vacuum is Drawn Resin Begins to Flow
Truck Trailer Bed and Supports
48‐Ft Composite Trailer Frame
Carbon Reinforced Lower Beams

People Movers (Atlanta, USA Airport)
Resin Film Infusion (RFI)
y Resin form very different – prepreg resin plates
y Resin “plates” pre‐loaded into rigid female tool cavity
y Complex fiber preforms loaded on top of resin plates
y Mold inserts, tooling pieces loaded into tool
y Flexible bagging installed over assembly
y Resin flows during heat‐up and cure cycle – through the
“thickness”
y Fibre volumes typically 50‐55% Vf
Basic RFI “Sequence”
1. Resin B‐staged panels (like tiles) laid out in tooling
mold bottom
2. Complex fibre preform installed on top of RFI resin
tiles
3. Tooling “inserts” installed to pre‐shape and hold
complex preform
4. Vacuum bagging materials installed
5. Assembly goes into autoclave for processing
6. Autoclave pressure and temperature cycle initiated
to (a) get resin to flow and (b) cure after infusion
Large Carbon Fiber Stitched Preform
for Wing Structure
y Textile 4‐head stitching machine at Boeing facility
y Can sew thickness up to 1.5‐inch
y Up to 3200 stitches per minute capability
Complex Preforms Required for RFI
y AS4 carbon fibre preforms
y Cross‐stiffened, stitched
preform for commercial
aircraft structures
y Provides complex structure
y Provide de‐bulked preform
y Used in resin film infusion
(RFI) process
Stitched Preform Lowered Into
Bottom RFI Tool
y Bottom mold RFI tool contains:
Hexcel 3501‐6 prepreg resin film plates installed
Stitched carbon preform placed above resin film (being
lowered into mold)
Inner Tooling, Inserts, Stitched
Preform Containment
y Inner mold line tooling placed within RFI mold
y Inserts and tool controls placed into position
y Stitched preform aligned dimensionally within tool
Reusable Silicone Vacuum Bag
Installation Completed
y Reusable silicone vacuum bag totally contains RFI part
y Multiple‐use silicone tooling works best
y Autoclave is next step in RFI process
Resin Film Infusion (RFI) Process for
High Performance
y RFI used in aerospace construction of large wings,
pressure bulkheads, etc.
y Resin film requires different process technique
y Resin viscosity extremely high at ambient temps
RFI Resins Must Be Processed Much
Differently
y RFI resins have too high viscosity for ambient temp flow
y Resin viscosity must be reduced by temperature
y Prepreg‐type resins and cure cycles may be used
Completed RFI Lower Wing Cover
(42‐ft, 12.8 m Section)
y 42‐ft length
y 8‐ft width
y Incorporates
damage tolerance
features
y RFI technology
demonstration
y Reduces `part‐count’
significantly
RFI Boeing Wing Section (Close‐up)
RFI Boeing Wing Section (Close‐up)
A340 NCF RFI Wingbox Demonstrator
Airbus A‐380 Aft Pressure Bulkhead
Preform Lay‐up on Infusion Tooling
RFI Resin on Tool
Completed A‐380 Pressure Bulkhead
Preformers Fall Into Several
Key Categories
Preform Type Approximate Usage (%)

Filament Winding 4
Knitting Techniques 13
2-D Braiding 13
3-D Braiding 4
Non-Woven 4
2-D Woven 22
3-D Woven 17
Stitched 23
Utilization of “Fabric” Preforms
Percent Industry
Fabric, Preform Type
Utilization (%)
45-Deg, Biased Fabric 14
Multi-Layer Materials 13
Knitted, Stitched 9
Twill Structures 6
Harness Satin Structures (4HS, 5HS) 18
Plain Weave 16
Uni-Tape/Unidirectional 15
Miscellaneous (Other) 10
Truss Core Fabric Preforms
y Truss core fabric
preforms available
y Glass
y Carbon
y Aramid
y Developed for
infrastructure
applications
y “Open” truss cores
Woven Fabric Preform Example
y Lower fibre content
overall
y More weaving
damage to fibre
y Compression strength
and stiffness lower
y “Knockdown” factors
not as good
Knitted Fabric Preform Example
y Knitted fabrics lightly
held together
y Polyester threads are
common
y Less out‐of‐plane
fibers
y Better compression
strength
y Improved strength
“knockdown” factors
Knitted Fabric Material Example
y Continuous preforming
process incorporates
numerous lay‐up options
y Continuous strand material
(CSM)
y 0/90° plus continuous mat
incorporated
y Knitted together (usually
tackified)
Fiberglass Preforms for Truck Door
y Low cost RTM preforms
y Chopped strand mat
(CSM) material
y Tackifier holds preforms
together during
handling
y Door for electric truck
y Moderate performance
structure ~ 50% fibre
Complex Glass Fibre Textiles
(with Molded‐In Fittings)
P4 Glass Fibre Automotive Preform
(P4‐A is Carbon Fibre)
Braiding Offers Low‐Cost Preforms
y Triaxial braiding
technology
y Net‐shape process
y RTM preforms are
available
y Low‐cost preforms
y Variety of materials:
y Carbon
y Glass
y Aramid
y Hybrids, Combinations
2‐D Braid Available in Many Forms and
Very Low Cost
y 2‐D braid materials are
low‐cost
y Used extensively in
RTM/VARTM
processing
y Variety braid materials:
y Carbon, graphite
y Glass
y Aramid
y Polyethylene
2D Braided Window Frame
(Commercial Aircraft)
y Carbon fibre 2D braid
structure
y Commercial aircraft
window frame
y Inherent structural
integrity around
window
y RFI approach used to
process rapidly
Close‐up of Triaxial 3D Braiding
y J‐frame carbon fiber
preforms
y 3D triaxial braiding
gives preform stability
in 0‐deg direction
y Invar tooling mandrel
inserted
3D Woven Structures
Existing Aluminium Fitting Was Expensive
Machined Part Requiring Numerous
Fibre Placement Process
Assembly of Complete Preform
Bearing Reinforcement Hinge Rib

Baseplate
Complete Preform
Completed Center Fitting with
Bearings
Summary
y Infusion processes vary – but there typically exist four (4)
nominal families:
y RTM (pressure)
y VARTM (vacuum)
y SCRIMP (vacuum with flow media)
y RFI (prepreg resin, vacuum, autoclave)
y Distinctions between commercial and aerospace in:
y Preform complexity
y Resin types
y Fibre volumes desired
y Structural aspects and performance enhancement
y Overall economics
Summary of Key Processes
Process & Product
RTM VARTM SCRIMP RFI
Variables
Liquid Molding/Resin Pressure Vacuum Vacuum Prepreg

“Infusion” Method (50‐500 psi) (to 29 in Hg) (to 29 in Hg) Resin Plates
Rigid, 1 Side,
Rigid, 2 or 1 Side Rigid, 1 Side Rigid, Tooling
Tooling Approach
more Sides Bagging Bagging Inserts,
Autoclave
Nominal Fibre Volume
55‐65+ 45‐55 45‐55 50‐55
Levels, Vf (%)
Dominant Market Aerospace Commercial Commercial Aerospace
Technical References
y “Resin Transfer Molding,” SAMPE Monograph #3, W.
Benjamin & S. Beckwith, SAMPE Publishing, 1999, ISBN
0‐938‐99483‐2
y “Resin Transfer Moulding for Aerospace Structures,” T.
Kruckenberg & R. Paton, Kluwer Academic, 1998, ISBN
0‐412‐73150‐9
y “Resin Transfer Moulding,” K. Potter, Chapman & Hall,
1997
y Extensive variety of SAMPE Symposium and Technical
Conference Proceedings (1990‐2010), www.sampe.org
y Roll wrapping
y Faster than filament winding
y Limited to symmetrical mandrels
Technology Assessment
Consumer Marketplace
Table Rolling (Golf Shafts)
Technology Assessment
Consumer Marketplace
Bladder Molding (Baseball Bats)

Manufacturing

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Vacuum Bagging

Prepreg Wet Resin

Placement of Dry Reinforcement

Build Up Required Thickness

Resin Impregnation Part Cure

Automated Ply Cutting

Autoclave Curing Cured Laminate

Porous Release Material

Double Sided Tape

Tool Double Sided

Double Sided Tape

Tool Double Sided

Another problem that can be encountered is blockage (large parts

More Messy ???

Layup tool for large wing skin

Mfg Certified TCR Delivered

Toray T1000GB 12K-40D 911 845 93

Toray M30SC 18K-50C 823 780 95

Toray M30GC 18K-11E 739 655 89

Toray T700SC 12K-50C 720 685 95

Toho G30-700 12K 689 628 91

Grafil 34-700 12K 646 534 85

Thornel T300C 12K 500 448 90

Mitsubishi TRH-50 12K 735 654 89

Mitsubishi TR-50S 12K 683 583 85

 Resin content can be specified  Operators must adjust “doctor

• The tack from

 Achieved though good alignment

 Coefficient of Variation (CV)  Winding operators require many

 Initial low raw material  Requires resin mixing

Decades of technical development provide a strong

Accumulator bottles Risers (drill & production)

Air Weight, (lb/ft) 28 65

Water Weight (lb/ft) 13 55

>160,000 cycles (required: 140,000 cycles)

 Showing 90° & 45°

 Small fixed width fiber

Injection Molding 15-30 Liquid resin, short fibres

Liquid resin, fibre

High Performance Marine

Large Sailing Vessels (e.g. Mirabella - 100m Mast)

Carbon Reinforced Lower Beams

RFI Resin on Tool

Preform Type Approximate Usage (%)

Bearing Reinforcement Hinge Rib

Liquid Molding/Resin Pressure Vacuum Vacuum Prepreg

Dominant Market Aerospace Commercial Commercial Aerospace

Table Rolling (Golf Shafts)

Bladder Molding (Baseball Bats)

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Resin content can be specified Operators must adjust “doctor

Achieved though good alignment

Coefficient of Variation (CV) Winding operators require many

Initial low raw material Requires resin mixing

Showing 90° & 45°

Small fixed width fiber