Overview of

Composite Materials &

Autoclave Method

Deepak Parshrampuria
2008JE0717
3rd year
Mechanical Engg.
COMPOSITE MATERIAL:

Composite materials generally consist of two different materials that are

combined together. In engineering, the definition can be narrowed down to a
combination of two or more distinct materials into one with the intent of
suppressing undesirable constituent properties in favour of desirable ones.
Atomic level combination such as metal alloys and polymer blends are excluded
from these definitions. Eg. Wood, R.C.C

Composites are made up of individual materials referred to

as constituent materials. There are two categories of constituent materials:
matrix and reinforcement. At least one portion of each type is required. The
matrix material surrounds and supports the reinforcement materials by
maintaining their relative positions. The reinforcements impart their special
mechanical and physical properties to enhance the matrix properties. A
synergism produces material properties unavailable from the individual
constituent materials, while the wide variety of matrix and strengthening
materials allows the designer of the product or structure to choose an optimum
combination.

Most commercially produced composites use a polymer matrix material

often called a resin solution. There are many different polymers available
depending upon the starting raw ingredients. There are several broad categories,
each with numerous variations. The most common are known as polyester,
vinyl ester, epoxy, phenolic, polyimide, polyamide, polypropylene, PEEK, and
others. The reinforcement materials are often fibres but also commonly ground
minerals. The various methods described below have been developed to reduce
the resin content of the final product, or the fibre content is increased. As a rule
of thumb, lay up results in a product containing 60% resin and 40% fibre,
whereas vacuum infusion gives a final product with 40% resin and 60% fibre
content. The strength of the product is greatly dependent on this ratio.

POLYMER RESINS:

Polymer or plastics are high molecular weight compounds

consisting of many repeated small segments. These small segments are called
monomers. There are two different reactions that can be used to create all
modern polymers: poly condensation and poly addition. They can all produce
linear of branched polymer. The primary bonds formed between the molecules
are the stronger covalent bond. Sometimes secondary bonds (van der waal’s) are
also present. Thermoset material are only 50 to 500 times more viscous than
water and can impregnate the empty spaces between fibers readily. They do
require an additional curing. On the other hand thermoplastic material do not
require this step but are highly viscous. There viscosity can be as high as a
million time that of water. Hence it is difficult to make them flow.

Difference between thermoplastics and thermosets from processing viewpoint

Characteristics Thermoplastics Thermoset

Viscosity High Low
Initial state Usually solid Usually liquid
Post processing None Heat necessary
Reversibility Can be remelted and Once formed, virgin state
reformed can’t be recovered
Heat transfer Heat needed to melt Heat may be need to initiate
requirement cure
Processing Usually high Can be at RT
temperature
Usage Large volume in injection Mainly used in advanced
molding composite
Solidification Cooling for change of Extraction of exothermic
phase heat during curing

Epoxy: Epoxy is a copolymer; that is, it is formed from two different chemicals.
These are referred to as the "resin" and the "hardener". The resin consists of
monomers or short chain polymers with an epoxide group at either end. Most
common epoxy resins are produced from a reaction between epichlorohydrin
and bisphenol-A, though the latter may be replaced by similar chemicals. The
hardener consists of polyamine monomers, for example Triethylenetetramine
(TETA). When these compounds are mixed together, the amine groups react
with the epoxide groups to form a covalent bond. Each NH group can react with
an epoxide group, so that the resulting polymer is heavily crosslinked, and is
thus rigid and strong.
The process of polymerization is called "curing", and can be controlled through
temperature, choice of resin and hardener compounds, and the ratio of said
compounds; the process can take minutes to hours. Some formulations benefit
from heating during the cure period, whereas others simply require time, and
ambient temperatures.

Properties and typical application for commonly used polymer

Name Material Application Important Application

family temp. range properties examples
Polyacrylate Thermoplastic 70 Excellent optical Magnifying
properties, easy glasses
bonding
PVC Do 60 Good chemical Flooring
resistance material, tubing
Poly Do -100to 130 High strength Helmets, safety
carbonate and ductility glasses
Vinylester Thermoset 200 Room curing , Marin industry,
high chemical corrosion
resistance, good resistance tank
strength and and pipe
ductility
unsaturated Do 100-180 High tensile Structural parts
Polyester strength(=steel), for boats and
good chemical cars, fishing rod
resistance
Epoxy Do 80-200 Structural part in Helicopter rotor
airplanes with blades, fuselage,
high demand for as adhesive
stiffness and
strength

FIBERS: Glass and carbon are commonly used for the fibers. The fiber
material usually will not influence the modelling of the manufacturing process
in a very significant way. However, whether the fibers are continuous or
discontinuous will influence the process. If, the fibers are discontinuous their
aspect ratio (the ratio of fiber length to its diameter) will be important during
processing. The continuous fibers can be introduced into the polymer matrix as
unidirectional fiber arrays or utilizing appropriate fabrication methods like
weaving, braiding, etc. The short and long fibers are typically employed in
compression moulding and sheet moulding operations. These come in the form
of flakes, chips, and random mate (which can also be made from a continuous
fibre laid in random fashion until the desired thickness of the ply / laminate is
achieved).

PROCESSING TECHNIQUEs OF PMC:

 Filament winding
 Pultrution
 Resin transfer molding
 Compression molding
 Injection molding
 Hot press molding
 Wet lay-up method
 Vacuum bag molding
 Autoclave method

WET LAY-UP METHOD:

Fiber reinforcing fabric is placed in an open mold and then saturated with a wet
[resin] by pouring it over the fabric and working it into the fabric and mold. The
mold is then left so that the resin will cure, usually at room temperature, though
heat is sometimes used to ensure a proper curing process. Glass fibers are most
commonly used for this process. In open mold operation the release material is
used over the mold to ensure easy separation of composite from mold. Gel coat
is also provided for smooth surface finish of desired color. Care should be
exercised to ensure that no air bubbles are entrained between the gel coat and
fabric(mat type). Additional layers of the thickness of the mat or woven
material are added to achieve the desired thickness. :
 Versatility is the main advantage of this method. Virtually any
shape can be produced and capital costs are limited to that of the mould. The
technique has traditionally been used in a variety of small scale production and
is used to make common products like skis, canoes, kayaks, boat building
industry for production of large craft and surf boards. The main dis-advantage
lay in the difficulty of ensuring complete impregnation and the labour intensive
nature of much of the work.

VACUUM BAG MOLDING:

Vacuum bag molding has been considered both as an extension to hand lay-up
for increased consolidation, as well as a route for molding co-mingled and
prepreg materials. In this method vacuum is applied to eliminate the entrapped
gases and excess resin. First of all hand lay up is placed into a impermeable/
flexible film (made of, a non-adhering film of polyvinyl alcohol or nylon ) and
vacuum is introduced. After that the lay up is shifted to a heat treatment at
elevated temperature and pressure. The simplest arrangement involves a
directional hydraulic press. The addition of pressure further results in higher
fiber concentration and provides better adhesion between layers of sandwich
construction. Also known as vacuum bagging. Compared to hand lay-up, the
vacuum method provides higher reinforcement concentrations, better adhesion
between layers, and more control over resin/glass ratios. Advanced composite
parts utilize this method with pre-impregnated fabrics rather than wet lay-up
materials and require oven or autoclave cures.

Difference between vacuum and autoclave: vacuum bag is relatively quick

and easy to carry out while in autoclave it takes hours for curing that makes
autoclave expensive also. The lay up in autoclave is placed in large chamber
which can be pressurized. In vacuum bag composite produced suffer from
limitations in term of quality, shape and size.
AUTOCLAVE METHOD:

AUTOCLAVE: It is a large pressure vessel with a heating facility. It is usually

made as a cylindrical or axisymmetric tube with a door at one end. As the
autoclave must be strong at high temperatures as well, the autoclave is an
expensive piece of equipment usually made of welded steel. Temperatures and
pressures are of the order of 100-200degrees C and 500-600kPa respectively.
The size of an autoclave is largely depends upon the size of the part to be
produced. For example in aerospace industry, for airplane wings the size of
autoclave is 50m long and 30m dia geometry.

PRINCIPLE OF OPERATION: In this method the release film is applied on the

tool surface. The next stage involves cutting the pregreg(continuous
unidirectional fibers partially impregnated with uncured thermoset resin)layers
and stacking them in desired sequence to form composite lay up.The material is
covered with release film, bleeder and breather material and a vacuum
bag(generally made of silicon or nylon polymer). Vaccum bag is pulled on part
and complete mould is placed into an autoclave.
Peel plies: provide necessary surface texture and protect the part surface during
handling.
Release film: for easy removal of part from tool and to allow resin to flow into
the bleeders.
Bleeders: absorbs the excess resin from prepreg material/laminate.
Breather: distributes the vacuum over the surface area.

The curing step is initiated by exposing the assembly to elevated temperatures

and pressure for predetermined length of time. The goal is to consolidate and
solidify. The elevated temperature provides the heat to initiate the cure reaction
and applied pressure provides the force needed to drain the excess resin out and
to compress the voids. For thermoset composite this process is irreversible.
Hence it is necessary to subject the part to the correct pressure and temperature.
THREE STAGES OF AUTOCLAVE PROCESSING:

STAGE-1: It is a heating stage. At the same time the pressure is ramped up

inside the autoclave. The first temperature ramp and hold in this stage is for the
viscosity to go down and for the excess resin to flow vertically into the bleeder
film. The second ramp and hold initiates the polymerisation via cross linking.
The first stage ends when the temperature and pressure reach to predetermined
value.

STAGE-2: It is essentially a hold stage. The autoclave is maintained at

processing temperature and pressure to allow curing to occur. As the cure
reaction preceeds and generates heat due to polymerization.

STAGE-3: The temperature is lowered to allow the excess heat to diffuse

through the part but the pressure is maintained at the same level to restrict the
growth of voids. When curing reaction is completed, the temp and the pressure
of the part are lowered. The part is removed from autoclave.

PROCESS PARAMETERS:

 Raw material quality

 Part preparation and handling.
 Pressure and temperature of curing cycle imposed on autoclave.
MEASURE OF QUALITY OF THE PART PRODUCED:

 Final thickness or dimensions.

 Degree of cure and cross linking.
 Voids and porosity contents

ERRORS INVOLVED IN PROCESSING STEPS:

 Failure to clean the tool surface

 Failure to completely remove air pockets
 Incorrect orientation & inaccurate placement
 Failure to place ancillary material
 Improper sealing of vacuum bag

ADVANTAGES:

 modification of vacuum bag molding

 Consistent part quality and high fiber volume of prepreg material.
 process produces denser, void free moldings
 Epoxy resin (generally used) contains higher properties than conventional
resin.

DISADVANTAGES:

 High initial capital investment.

 Process is slow, labour intensive and medium size production.
 Mold is usually one sided, inability with complex geometry.
 Hand layup can introduce human errors which causes variety of defects.
 Confined application to only few industries.

APPLICATION OF COMPOSITE IN AIRCRAFT INDUSTRY:

According to Boeing, the new 787 Dreamliner will be more fuel efficient than
the comparable midsize 767 or Airbus A330 by using lighter-weight materials
and other engineering advances. Using layers of carbon fiber-reinforced plastic
forms a lighter and more durable body than aluminium, allowing for larger
windows, higher cabin pressure and higher cabin humidity. A one-piece
fuselage section eliminates 1,500 aluminum sheets and 40,000 to 50,000
fasteners. Composite planes are lighter and burn less fuel. Unlike metal,
composites don’t fatigue or corrode, meaning airlines will have to perform less
maintenance.
REFERENCES:

1. Suresh G. Asvani & E. Murat Sozer

2. Handbook of Polymer Composites for Engineers By Leonard Hollaway
Published 1994 Woodhead Publishing
3. Matthews, F.L. & Rawlings, R.D. (1999). Composite Materials:
Engineering and Science.
4. Autar K. Kaw (2005). Mechanics of Composite Materials (2nd ed.).