MANUFACTURING OF

COMPOSITE MATERIAL:
PRESENTED TO: Dr. NADEEM ZAFAR
PRESENTED BY: SAWERA YOUSAF-060
AMNA-070
SUBJECT: APPLIED CHEMISTRY
SEMESTER: BS(6TH)INDUCTION
UNIVERSITY OF GUJRAT
COMPOSITE MATERIAL:
A composite material is a combination of two
materials with different physical and chemical
properties. When they are combined they create a
material which is specialized to do a certain job.
 Fibreglass: Glass fibre combined with a plastic
which is relatively inexpensive and flexible.
 Carbon Fibre reinforced polymer: Carbon fibre set
in plastic which has a high strength-to-weight ratio.
MOLDING PROCESS:

Molding (American English) or moulding

(British and Commonwealth English; see spelling
differences) is the process of manufacturing by
shaping liquid raw material using a rigid
frame called a mold or matrix.
Figure 01: Steps in molding process:
FABRICATION PROCESS:
 Fabrication is the process of constructing
products by combining typically standardized
parts using one or more individual processes.
 For example, steel fabrication is the production
of metal structures using a range of processes
such as cutting, bending and assembling.
CONTINUE…….

The fabrication methodology of a composite part

depends mainly on three factors;
i. The characteristics of matrices and
reinforcements,
ii. The shapes ,sizes and engineering details of
products
iii.End uses.
FABRICATION OR
MANUFACTURING PROCESSES FOR
POLYMER MATRIX COMPOSITES:
Matched die mould- the common feature in this
technique is moulds are usually fabricated with cast iron,
steel and aluminum alloy.
Some of it includes
 Compression moulding,
 cold stamping,
 Press moulding and
 Injection moulding
Figure02: compression moulding
Figure03: cold stamp moulding
Figure04: press moulding
Figure05: injection moulding
Applications of match die mould
method:
Contact mould or Open mould-
In this there is only one mould, the surface of
which is first polished, cleaned and coated with a
release agent & gel.
The moulding materials are laid on the mould by
either the hand lay-up process or the spray-up
process.
 Some of its includes:
 Vacuum bag moulding
 Pressure bag moulding
FIGURE06: OPEN MOULDING PROCESS
Figure07: vacuum bag moulding
Figure08: pressure bag moulding
Applications of Contact mould
method:
  Filament moulding- The filament winding
process is employed for fabrication of a continuous
fiber reinforced composite structure having an axis of
revolution. Continuous fiber strands or rovings’ are
first coated with resin in a resin bath and then fed
through rollers to squeeze out excess resin and finally
wound, under constant tension, around a collapsible
mandrel.
 There are basically 2 types of filament winding
patterns: helical winding and biaxial winding.
 Common examples are tubes, pipes, cylindrical
tanks, pressure vessels, rocket motor cases, etc.
Figure09: a. Polar and hoop winding b. Helical
winding
FABRICATION OR MANUFACTURING
PROCESS FOR MEATL MATRIX
COMPOSITES:
 Aluminium, magnesium, titanium and nickel alloys
are commonly used as metal matrices, although
several other matrix materials including super alloys
have also been used. Both metal and ceramic
reinforcements are employed.
 Important moulding methods for fabrication of MMC
parts may be classified under:
 Diffusion bonding
 Powder metallurgy process
Figure10: diffusion bonding
Figure11: Powder metallurgy process
a. plasma spray technique b. arc spray technique
FABRICATION OR MANUFACTURING
PROCESSES FOR CERAMICS MATRIX
COMPOSITES: