National Institute of Science & Technology

Manufacturing Technique for

Thermoset Composite

By
K Nandini Dora
H Dharmendra Gupta
Sibasankar Mishra
Nilesh Dalai
[1]
 Content
National Institute of Science & Technology

• What is Composite?
• Merits of Composite Materials
• Classification of Composites
• Rule of Mixture
• Step Involved in Composite Manufacturing
• Composite Manufacturing Techniques
• Application, Advantages and Disadvantages of Various Processes
• Selection Criteria for Manufacturing Process
• Conclusion
• References

[2]
 What are Composites?
National Institute of Science & Technology

• Composite is a combination of two or more chemically distinct and insoluble

constituent materials or phases which must have significantly different properties in
order it to combine. But, metals and plastics are not considered as composites, as
they have a lot of fillers and impurities
• The properties and performance of composites are far superior to those of the
constituents
• Composites consists of one or more discontinuous phases (reinforcement)
embedded in a continuous phase (matrix)
• Examples:
Cemented carbides (WC with Co binder)
Rubber mixed with carbon black
Wood (a natural composite as distinguished from a synthesized composite)

[3]
 Merits of Composite Materials
National Institute of Science & Technology

 High specific strength and

 High specific stiffness and long fatigue life
 High creep resistance
 Low coefficient of thermal expansion
 Low density
 Low thermal conductivity
 Better wear resistance
 Improved corrosion resistance
 Better temperature dependent behavior

[4]
 National Institute of Science & Technology

Classification of Composites

[5]
 National Institute of Science & Technology

Rule of Mixtures

[6]
 Steps involved in a Composite Manufacturing Process
National Institute of Science & Technology

1. Impregnation : Lamina is formed by mixing resin and fiber.

The viscosity, surface tension and capillarity action of resin
and strength of the fiber should be maintained in this step.
2. Lay up : The desired Fiber orientation angle is achieved.
3. Consolidation : It ensures that there is no air molecules,
voids are trapped inside the composite.
4. Solidification : It’s rate depends on curing rate, resin to fiber
ratio and curing method.

[7]
 Composite Manufacturing Techniques
National Institute of Science & Technology

The composite manufacturing technique is basically of two

types:
I. Open molding
 Hand lay-up process
 Spray up process
 Filament winding process

II. Close molding

 Pultrusion method
 Compression molding process
 Vacuum impregnation process

[8]
 Open molding
National Institute of Science & Technology

• In this process, the raw materials like the fiber reinforcements

and resins are exposed to the air while curing or hardening.
• It includes different processes like hand lay-up process, spray
up and filament winding Technique.

[9]
 Hand lay-up process
National Institute of Science & Technology

.
• Applications:
 Used in aerospace industry
 Manufacturing structures like wing
structures, yacht and sporting goods.
• Advantages:
 Very strong and stiff, so used for making
prototype parts.
• Disadvantages:
 It is very expensive
 Not suitable for high volume production.

[10]
 Spray up process
National Institute of Science & Technology

Applications:
 It is used in swimming pools, bath tubs, storage
tank, duct furniture, etc.
Advantages:
 Low cost tooling.
 It is suitable for high structural requirement.
Disadvantages:
 Due to open mold, styrene extraction is difficult.
 It is also difficult to control the thickness and the
fiber volume fraction.

[11]
 Filament Winding Process
National Institute of Science & Technology

. Applications:
 Used in chemical storage tank, rocket launch
tubes, tubular structures, pressure vessels
Advantages:
 It is used to make high-performance composite
and cost-effective parts like pressure vessel.
Disadvantages :
 Maximum fiber volume fraction attained is
only 60%.
 Low fiber angle are not easily produced.
 Difficult to obtain uniform fiber distribution.

[12]
 Close Molding
National Institute of Science & Technology

• In this molding, the raw materials like resin and fiber are cured
inside a two-sided vacuum bag or mold where air is not
allowed.
• These processes are usually automated and require special
equipment in order to produce high volumes of materials.

[13]
 Pultrusion process
National Institute of Science & Technology

.
Application:
 Beams, Channels, Tubes, handrail, Ladder
Advantages:
 It can even fabricate transportable length
parts, and complex thin walls.
 It can use wide variety of reinforcement
types.
• Disadvantages:
 It becomes difficult to maintain tight
tolerances
 Difficult to control the shrinkage.
[14]
 Compression Molding Process
National Institute of Science & Technology

,
• Advantages of Molding
• Less labor is required
• Production is faster
• Density is uniform
• Disadvantages of Molding
• Not very suitable to produce very
large sized products
• Large curing time
• Uneven parting lines are present

[15]
 Vacuum Impregnation Methods
National Institute of Science & Technology

Advantage
 It is cost effective and efficient.
Disadvantage
 High risk associated with part washing and
rinsing.
Application
 it is used to reduces the water activity.

[16]
 Selection Criteria for Manufacturing Process
National Institute of Science & Technology

[17]
 Comparison of Various methods according to Cycle time
National Institute of Science & Technology

[18]
 Comparison of Various methods according to factor of properties
National Institute of Science & Technology

[19]
 Production of various parts in Automobile industry
National Institute of Science & Technology

[20]
 Energy intensities of manufacturing processes
National Institute of Science & Technology

[21]
 Conclusion
National Institute of Science & Technology

Selection criteria for manufacturing methods depends on various

factors. The raw material and reinforcement play the main role on
deciding the manufacturing methods. There are also some other factor
like Shape, Size, Strength, Production rate and cost are also consider
while choosing a correct manufacturing method.

Ex:-
 In Pultrusion process the Chopped/ Short fiber filler composite
can’t produced.
 In Filament winding process it is very difficult to prepare flat
element.
[22]
 References
National Institute of Science & Technology

1. J. Frketic. Et.al. Automated Manufacturing and Processing of Fiber-Reinforced Polymer (FRP)

Composites: An Additive Review of Contemporary and Modern Techniques for Advanced
Materials Manufacturing, Additive Manufacturing,
2. S. K. Mazumdar, Composites Manufacturing Materials, Product and Process Engineering, CRC
Press
3. F.C. Campbell, Manufacturing Process for Advanced Composite, Elsevier
4. R. M. Jones, Mechanics of Composite Materials, Taylor & Francis
5. K. K. Chawla, Composite Materials, Springer
6. F Hamidi, F Aslani, Review Additive manufacturing of cementitious composites: Materials,
methods, potentials, and challenges, Construction and building Materials (218) 582-609
7. S B Yang et. al. Simple manufacturing method for a thermoplastic composite using PP-Straw,
Composites Part B: Engineering (176) 107183
8. F.X.Irisarri et. al. A novel design method for the fast and cost-effective manufacture of composite
parts employing the Quilted Stratum Process, Composites Part B: Engineering (158) 364-372

[23]
 National Institute of Science & Technology

[24]