Module 3 25 36

02-03-2023
Transfer Moulding
• The mold cavity is filled with preformed reinforcing fibers.
• A pre-weighed amount of a polymer mixed with additives and fillers
(charge) is placed into the transfer pot.
• The charge may be in form of powders, pellets, putty-like masses or
pre-formed blanks.
• The charge is heated in the pot where the polymer softens.
• The plunger, mounted on the top plate, moves downwards, pressing
on the polymer charge and forcing it to fill the mold cavity through the
sprue and impregnate the fibers.
• The mold, equipped with a heating system, provides curing (cross-
linking) of the polymer (if thermoset is processed).
Source: https://www.substech.com/dokuwiki/doku.php?id=closed_mold_fabrication_of_polymer_matrix_composites
Dr. Sreekanth. M. P 49
Transfer Moulding
• The mold is opened and the part is removed from it by means of the ejector pin.
• If thermosetting resin is molded, the mold may be open in hot state – cured
thermosets maintain their shape and dimensions even in hot state.
• If thermoplastic is molded, the mold and the molded part are cooled down
before opening.
• The scrap left on the pot bottom (cull), in the sprue and in the channels is
removed. Scrap of thermosetting polymers is not recyclable.
• Transfer Molding cycle time is shorter than Compression Molding cycle but
longer than Injection Molding cycle.
• The method is capable to produce very large parts (car body shell), more
complicated than Compression Molding, but not as complicated as Injection
Molding.
Source: https://www.substech.com/dokuwiki/doku.php?id=closed_mold_fabrication_of_polymer_matrix_composites
25
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Transfer
Moulding
Source:
https://slideplayer.com/
slide/7590435/
BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)
• This is a closed mould process and is adopted to make

composites where high reinforcement to resin ratio is required.
• Also certain composite systems like carbon fiber, boron fiber
and silica fiber reinforcements in high molecular polymer resin
will require better compaction and continuous removal of
entrapped air and volatile substances.
• This process also provides smooth and textured finishes on all sides
and is better suited for automation.
• Basically Bag Moulding comprises of three different methods as
under: Vacuum Bag moulding, Pressure Bag moulding, and
Autoclave moulding.
Source: https://www.studocu.com/in/document/pes-university/composite-materials/bag-moulding-process-prof-supriya/17819820
26
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• Prepregs are laminate

composites of fiber sheets
that are impregnated with
polymer resins (plastics)
that have not been fully
cured. Fiber sheets are
often fiberglass, carbon
fiber, or polyaramid (Kevlar).
Materials in this form are
often called B-staged.
Source: https://www.sciencedirect.com/topics/materials-science/prepreg
Source: https://slideplayer.com/slide/4452286/
27
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• If only Vacuum is used with atmospheric pressure, the technique is

called Vacuum Bag Moulding.
• If air at room temperature is used to pressurize then the
technique is referred to as Pressure Bag Moulding.
• If hot gases are used in closed chamber, then the technique is
called as Autoclave Bag Moulding.
• One of the oldest and versatile process for consolidating pre-
impregnated laminates (prepregs). The prepregs are cut to
suitable size & shape, laid up on a mould, covered by a flexible
diaphragm, cured under high pressure and temperature.
• Bagging technique requires considerable skill on the part of the

worker to produce high quality finished product.
• Vacuum bag moulding requires simple instruments and handles
large parts and complex shapes.
• Pressure bag and Autoclave are preferred for curing at higher
pressures and temperatures and for higher level of consolidation .
E.g. Helicopter blades, Helicopter rotor shafts, Instrument panels for
Aircrafts, Truss members for Satellites etc.
• Pressures up to 640 MPa and Temperatures up to 200°C can be
achieved in Autoclave.
• Heated air or steam is used for pressurization.
28
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Vacuum
Bag
Moulding
Atmospheric pressure is used. Air is removed from the mould cavity. The pressure
difference cause the lay – up to fill in the cavity.
Dr. Sreekanth. M. P Source: Composite Materials: Production, Properties, Testing, and Applications – K Srinivasan – 2009 – Narosa Publishing House Pvt. Ltd. 57
Vacuum
Bag
Moulding
Source:
https://slideplayer.com/slide/4452286/
29
02-03-2023
Pressure
Bag
Moulding
Pressure Greater than Atmospheric pressure is used. No Autoclave is used.

Economical. A flexible bag is placed over the lay – up, which is one the mould. Gas
is pumped into the bag. This will compress the lay – up into the mould.
Pressure
Bag
Moulding
Dr. Sreekanth. M. P Source: https://www.slideshare.net/Lahiru_Dilshan/vacuum-bag-forming-and-pressure-bag-forming 60
30
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Autoclave Moulding
An autoclave is a machine used to

carry out industrial and scientific
processes requiring elevated
temperature and pressure in relation
to ambient pressure and/or
temperature
Pressure Greater than Atmospheric pressure is used. Mould and lay – up kept
inside the clave. Gas with high pressure is pumped into the autoclave and above
the lay – up. High pressure gas press the lay – up against the mould.
Autoclave Moulding
Source:
https://www.slideshare.net/Ma
nojK55/autoclave-molding
31
02-03-2023
Pultrusion
Process
Source: http://www.substech.com/dokuwiki/doku.php?id=pultrusion
Pultrusion Process
• Pultrusion is an automated, highly productive process of fabrication

of Polymer Matrix Composites in form of continuous long products of
constant cross-section.
Pultrusion process involves the following operations:
• Reinforcing fibers are pulled from the creels.
• Fiber (roving) creels may be followed by rolled mat or fabric creels.
• Pulling action is controlled by the pulling system.
• Guide plates collect the fibers into a bundle and direct it to the resin
bath.
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02-03-2023
Pultrusion Process
• Fibers enter the resin bath where they are wetted and impregnated
with liquid resin.
• Liquid resin contains thermosetting polymer, pigment, fillers, catalyst
and other additives.
• The wet fibers exit the bath and enter preformer where the
excessive resin is squeezed out from fibers and the material is
shaped.
• The preformed fibers pass through the heated die where the final
cross-section dimensions are determined and the resin curing
occurs.
• The cured product is cut on the desired length by the cut-off saw.
Pultrusion Process
Pultrusion process is characterized by the following features:
• High productivity.
• The process parameters are easily controllable.
• Low manual labor component.
• Precise cross-section dimensions of the products.
• Good surface quality of the products.
• Homogeneous distribution and high concentration of the reinforcing
fibers in the material is achieved.
• Pultrusion is used for fabrication of Fiber glasses, Carbon Fiber
Reinforced Polymer Composites and Kevlar (aramid) fiber reinforced
polymers.
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02-03-2023
Pultrusion
Process
Source:
https://slideplayer.com/slid
e/10477852/
Filament
Winding
Process
Source: https://www.researchgate.net/figure/FRP-composite-manufacturing-process-of-filament-winding-2_fig2_335601265
34
02-03-2023
Filament Winding Process
• Filament winding is an automated method for creating composite

structures by winding filaments under tension over a rotating
mandrel (tool).
• The fiber placement is guided by a machine with two or more axes
of motion.
• Filament winding a used to manufacture a range of products such as
pipes, pipe joints, drive shafts, pressure vessels, storage tanks etc.
• There are a number of different types of filament winding machine
that are best suited to manufacturing different type of components.
Source: https://www.cadfil.com/filamentwindingprocess.html & https://www.azom.com/article.aspx?ArticleID=352

• The mandrel can be any shape that does not have re – entrant
curvature.
• It is possible to remove the component from the mandrel before it
has cured and use some other means of compaction to produce
reverse curvature if required.
• The fibers may be impregnated with resin before winding (wet
winding), reimpregnated (dry winding) or post impregnated.
• Wet winding has the advantages of using the lowest cost materials
with long storage life and low viscosity.
• The prepreg systems produce parts with more consistent resin
content and can often be wound faster.
Source: https://www.azom.com/article.aspx?ArticleID=352
35
02-03-2023
• Glass fiber is the fiber most frequently used for filament winding,
while carbon and aramid fiber are also used.
• Most high strength critical aerospace structures are produced with
epoxy resins, with either epoxy or cheaper polyester resins being
specified for most other applications.
• The component is normally cured at high temperature.
• Finishing operations such as machining or grinding are not normally
necessary.
Source: https://www.azom.com/article.aspx?ArticleID=352
Filament
Winding
Process
Source:
https://slideplayer.com
/slide/4452286/
36

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02-03-2023

BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)

• This is a closed mould process and is adopted to make

BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)

• Prepregs are laminate

BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)

BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)

• If only Vacuum is used with atmospheric pressure, the technique is

BAG MOULDING PROCESS (PREPREG LAY-UP PROCESS)

• Bagging technique requires considerable skill on the part of the

Pressure Greater than Atmospheric pressure is used. No Autoclave is used.

Dr. Sreekanth. M. P Source: https://www.slideshare.net/Lahiru_Dilshan/vacuum-bag-forming-and-pressure-bag-forming 60

An autoclave is a machine used to

• Pultrusion is an automated, highly productive process of fabrication

Filament Winding Process

• Filament winding is an automated method for creating composite

Filament Winding Process

Filament Winding Process

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