Institut Kemahiran Belia Negara Pekan

Jabatan Penyelenggaraan Pesawat

Bahagian Composite Repair

CURING PROCESS – COLD BOND

6. VACUUM BAGGING MATERIALS
 VACUUM BAGGING MATERIALS
• Introduction • Vacuum Gauges
• Mold Release Agent • Vacuum Pumps
• Peel Ply or Release • Resin
Fabric • Vacuum Leak Detectors
• Perforated Release Film • Vacuum Valves
• Bleeder Layer • Vacuum Hose
• Separator Film Layer • Resin Traps
• Breather Layer • Manifolds
• Sealant Tape • Vacuum Bagging Film
 INTRODUCTION VACUUM BAGGING
MATERIALS
• Vacuum bagging materials such as bag sealant tapes, peel ply,
release film, bleeder cloth are all known as composite
consumables and are used to achieve a vacuum, extract
moisture, solvents, and volatiles from the curing composites,
and then retrieve the composite structures from the
composite molds afterwards
 MOLD RELEASE AGENT
• Mold release is essential for preventing the epoxy from
sticking to the mold when laminating a part.
• The most common type is a carnauba based paste wax. This is
usually put on in up to 5 layers for new molds and at least one
layer before each new part is molded.
• The second type of release is the semi-permanent
formulation.
• The final type of mold release is of the general contaminant
variety. This can range from things like grease and Vaseline to
toilet bowl wax, hair spray, hair gel or even clear packaging
tape.
 PEEL PLY @ RELEASE FABRIC
• They are placed against the laminate to provide a molded
surface suitable for secondary bonding or painting.
• They can be applied dry or impregnated with the same
resin as the laminate.
• A porous peel ply is used when you do not wish to
restrict the resin bleed and/or a peel ply surface texture
is required.
• A non-porous peel ply (commonly known as FEP,
fluorinated ethylene propylene, or Teflon®) is used when
no resin bleed is required, but evacuation of the volatiles
and solvents is desired
PEEL PLY @ RELEASE FABRIC
 PERFORATED RELEASE FILM
• This is a thin plastic which has been treated so it won't bond
to the laminate. It is highly stretchable so it can conform to
complex geometries.
• Release films are used to control resin flow during cure and to
release the vacuum consumable lay up from the laminate
following cure.
 BLEEDER LAYER
• The bleeder layer is used to absorb resin from the laminate
either through a porous peel ply or a perforated release film.
• The bleeder layer is usually a non-woven synthetic fiber
material that comes in a variety of different thicknesses
and/or weights.
 SEPARATOR FILM LAYER
• The separator layer is used between the bleeder layer and the
subsequent breather layer to restrict or prevent resin flow.
• This is usually a solid or perforated release film that extends
to the edge of the layup, but stops slightly inside the edge of
the bleeder layer, to allow as gas path to the vacuum ports.
 BREATHER LAYER
• The breather layer is used to maintain a "breather" path
throughout the bag to the vacuum source, so that air and
volatile can escape, and so continuous pressure can be
applied to the laminate.
• The breather layer usually extends past the edges of the layup
so that the edge-band makes contact with the bleeder ply
around the separator film.
 SEALANT TAPE
• Also none as “tacky tape”, it is used to provide an airtight seal
between the tool / master model and bagging film.
• The tape must have sufficient tack to adhere well to the mold
surface but not so much tack that the bag cannot be stripped
away from the tape for re-positioning during layup.
 VACUUM BAGGING FILM
• Vacuum bagging film is the final layer of material applied and
secured to the tool using sealant tape.
• These materials are used to form the vacuum bag. The bag
film is used as the vacuum membrane that is sealed at the
edges to either the mold surface .
 VACUUM VALVES
• Vacuum valves are the attachment points between the
bagging film and the vacuum hose.
• “VAC VALVES” can be simple nylon thru-hull fittings or
elaborate quick release valves used by aerospace, which seal
positively and may be disconnected without bleeding
pressure.
 VACUUM HOSE
• Vacuum hose may be flexible or rigid. Commonly, vacuum
hose is made from PVC tubing and connected to the vacuum-
valve by a short run of flexible hose.
 RESIN TRAPS
• Resin traps should be fitted in the vacuum hose between the
part and the vacuum pump.
• This will stop any resin from migrating from the part to the
pump.
• This is simply a closed cup with the vacuum hose entering and
exiting at the top so that any resin which moves through the
vacuum hose will drop into the cup before it can flow to the
vacuum pump.
 MANIFOLDS
• Manifolds are required where multiple vacuum hoses and
valves are used to evacuate the part.
• The manifold should be fitted with a valve on the pump side
and a vacuum pressure gauge.
 VACUUM GAUGES
• Vacuum gauges should be located at the pump, at the
manifold if one exists, and on the part.
• This will give the builder an idea of pressure exerted on the
part as well as if some portion of the bag has been pinched off
and is not drawing vacuum equally from all areas of the bag.
 VACUUM PUMPS
• Vacuum pumps must fulfill two capacities. First, they must be
capable of a high vacuum, at least 13 psi.
• Second, they must be able to evacuate a large volume of air
quickly.
 RESIN
• Resin can be used either epoxy of vinylester/polyesters can be
used. Epoxies are best, giving plenty of time to bag, and they
do not attack PVC foam.
• Vinylesters/polyesters will attack PVC foams after a period of
time, in a process called styrene migration
 VACUUM LEAK DETECTORS
• Composites repair equipment such as vacuum leak detectors
are commercially available to assist with the technicalities of
the controlled conditions necessary for successful composites
vacuum bagging.
• Ultrasonic vacuum leak detectors will pick up the high pitched
sound of air escaping from the bag.
THANK YOU

Q & A SECTION