MM3FRC: Fibre Reinforced Composites

Lecture 11: Composites Manufacturing:

State of the Art 2015

Prof Nick Warrior

nick.warrior@nottingham.ac.uk

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Learning Outcomes

• Taking the material from Lectures 3 and 4 to give

an understanding of the current state of the art of
manufacturing processes for carbon fibre
composite materials

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Composite Pre-pregs
HEXPLY® AEROSPACE PREPREGS
http://www.hexcel.com/Resources/DataSheets/Brochure-Data-Sheets/Prepreg_Technology.pdf

EPOXY – Good mechanical properties (Max service temp 100 oC for – 120oC curing
epoxy, max service temp 130oC – 155oC for 180oC curing epoxy)

HexPly® M26T BISMALEIMIDE BMI – good resistance to high temperatures (Max service temp
HexPly®M76 o
260 C)
HexPly®913
HexPly®M20 HexPly® M65

HexPly®8551-7
o o
HexPly®F593 PHENOLIC – good fire resistance (Max service temp 80 C – 100 C)

HexPly®M21 HexPly® HT93

HexPly®M56 HexPly® 200
HexPly®M91
HexPly®8552 - US; EU o
CYANATE ESTER – good dielectric properties (Max service temp 200 C)
HexPly®M18 - US; EU
HexPly® 996
HexPly®922-1
3

HexPly®M18/1 HexPly® 954-3

Autoclave process for prepregs

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Prepreg Storage and Handling
Prepregs are stored in a freezer at -18°C. (typically have a shelf life
at -18°C for 12 months from date of manufacture).

Prepreg stored in sealed polythene bag to avoid moisture

contamination.

When removed from freezer allow the prepreg to reach room

temperature before opening the polythene bag. (A full roll in its
packaging can take up to 48 hours).

Tack Life: The time, at room temperature, during which the prepreg
retains enough tack for easy component lay-up
Out life: The maximum accumulated time allowed at room
temperature between removal from the freezer and cure.

Record time out of the freezer!

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 Layup / laminating
Hand laminating
https://www.youtube.com/watch?v=504I_hJDFck
https://www.youtube.com/watch?v=PGGiuaQwcd8
Automated Tape Laying (ATL)
https://www.youtube.com/watch?v=-qAaJwm11dg
https://www.youtube.com/watch?
v=ehfCEz_OfDU&index=5&list=PL4CE1BD7CFB587FA
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Automatic Fibre Placement (AFP)
https://www.youtube.com/watch?
v=QDbrVTWnFIU&list=PL4CE1BD7CFB587FA9
5/12/20 https://www.youtube.com/watch?v=8x33qM_QbwM 6

https://www.youtube.com/watch?v=h5vasU-N1ps
Laminating prepreg

Cut with a sharp tool (blade, ultrasonic cutter

https://www.youtube.com/watch?v=-Zed4z-a0kU

Prepreg can be high, medium or low tack.

Prepreg protective film is removed before laying-up.

Individual ply components precisely placed to create final
laminate

Automated lay-up used for increased productivity, reliability

and accuracy of lay-up.
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 Vacuum bag within autoclave

5/12/20 8
 Carbon Fiber Construction - /Inside Koenigsegg

https://www.youtube.com/watch?v=504I_hJDFck

Making 280mph Capable Carbon Fiber Wheels -

/INSIDE KOENIGSEGG

https://www.youtube.com/watch?v=PGGiuaQwcd8

5/12/20 9
Autoclave cure cycles

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A typical autoclave cure cycle for a thin laminat of (80-180oC curing epoxy matrix is
 Typical autoclave cure cycles
o
A typical autoclave cure cycle for a thin laminate of 80-180 C curing epoxy matrix is 90
o o
minutes at 135 C and for a thick (>10mm) laminate is 180 minutes at 120 C.

Alternative cure cycles can be used e.g.

o
Cure can be followed by a free-standing post-cure for 2 hours at 180 C to achieve a higher

glass transition temperature.

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Inspection of Carbon Composites

Non Destructive Evaluation Destructive

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Composite Liquid Moulding
Resin Transfer Moulding technology is well-known – increasing interest in

High Pressure RTM (HP-RTM)

• RTM injects at 10 to 20 bar - has a standard cycle time of 30 to 60 minutes

• HP-RTM uses up to 150 bar in the mixing head and between 30 to 120 bar
• inside the tool - cycle times of less than 10 minutes

Offers the opportunity to use snap-cure resin systems

EPIKOTE Resin 05475/EPIKURE Curing Agent 05500

• o
1-minute injection window and 2-minute cure at 120 C.

Dow Automotive Systems - VORAFORCE 5300 epoxy

• sub 60-second mould cycle 13
HP-RTM system manufacturers
Dieffenbacher/KraussMaffei, Engel

80 Second Cycle Time Epoxy RTM Structural Composite

Demonstration

https://www.youtube.com/watch?v=lgtjkpySvhY

BMW i production RTM Press

https://www.youtube.com/watch?v=J-c9_DNzD0s
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 Composite Compression Moulding
From Dr Lee Harper

Carbon SMC manufacturers: Hexcel, Quantum, Menzolit, Tencate

Structural applications:
• Boeing 787 window surround
• Lamborghini Sesto Elemento,

Typically derived from UD prepregs, therefore expensive (> £UD)

Very limited charge flow compared with glass SMCs

• High charge coverage required
• High resin viscosity required to prevent fibre/matrix separation

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Combination of prepreg and C-SMC

• Prepreg Compression Moulding – Mitsubishi

• Prepreg and C-SMC co-moulding

• o
Rapid curing prepregs (2 mins @150 C)

• Expensive material formats

• Rapid preforming solution for 2D/3D charge creation

Lamborghini Sesto Elemento

Forged Composites
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Machining of finished parts

Cured carbon fibre difficult to machine

Rotary machining
High speed spindle with cutting tool (carbide or
diamond coated)

Waterjet
abrasive powder in water stream at high
pressure 700 MPa)
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Lecture 11 Assessment
• Name

• Student ID

• Signature

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Lecture 11 Assessment

• Q1

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Lecture 11 Assessment

• Q2

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Lecture 11 Assessment

• Q3

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