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Manufacturing Processes for Advanced Composites
 
 

Manufacturing Processes for Advanced Composites, 1st Edition

 
Manufacturing Processes for Advanced Composites, 1st Edition,Flake Campbell Jr,ISBN9781856174152
 
 
 

F Campbell Jr   

Elsevier Science

9781856174152

9780080510989

532

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Description

• One of very few books available to cover this subject area.

• A practical book with a wealth of detail.


This book covers the major manufacturing processes for polymer matrix composites with an emphasis on continuous fibre-reinforced composites. It covers the major fabrication processes in detail.


Very few books cover the details of fabrication and assembly processes for composites. This book is intended for the engineer who wants to learn more about composite processing: any one with some experience in composites should be able to read it. The author, who has 34 years experience in the aerospace industry, has intentionally left out mathematical models for processes so the book will be readable by the general engineer.


It differs from other books on composites manufacturing in focussing almost solely on manufacturing processes, while not attempting to cover materials, test methods, mechanical properties and other areas of composites.

Readership

Materials engineers; manufacturing engineers; design engineers; structural engineers; mechanical and chemical engineers; production supervisors and consultants.

Flake Campbell Jr

Affiliations and Expertise

Senior Technical Fellow at the Boeing Phantom Works in Missouri, USA.

Manufacturing Processes for Advanced Composites, 1st Edition

Chapter 1 - Introduction to Composite Materials and Processes

Laminates

Fibers

Matrices

Product Forms

Overview of Fabrication Processes

Advantages and Disadvantages of Composites

Applications

Summary

Acknowledgement

References


Chapter 2 - Fibers and Reinforcements

Fiber Terminology

Glass Fibers

Aramid Fibers

Ultra-High Molecular Weight Polyethylene (UHMWPE) Fibers

Carbon and Graphite Fibers

Woven Fabrics

Reinforced Mats

Chopped Fibers

Prepreg Manufacturing

Summary

References


Chapter 3 - Thermoset Resins

Thermosets

Polyester Resins

Epoxy Resins

Bismaleimide Resins

Cyanate Ester Resins

Polyimide Resins

Phenolic Resins

Toughening Approaches

Physiochemical Characterization and Quality Control

Chemical Testing

Rheological Testing

Thermal Analysis

Glass Transition Temperature

Summary

References


Chapter 4 - Cure Tooling

General Considerations

Thermal Management

Tool Fabrication

Summary

References


Chapter 5 - Ply Collation

Prepreg Control

Tool Preparation

Manual LayUp

Ply Collation

Flat Ply Collation and Vacuum Forming

Automated Tape Laying

Filament Winding

Fiber Placement

Vacuum Bagging

Summary

References


Chapter 6 - Curing

Cure of Epoxy Composites

Theory of Void Formation

Hydrostatic Resin Pressure Studies

Chemical Composition Variables

Net and Low Flow Resin Systems

Resin and Prepreg Variables

LayUp Variables

Debulking Operations

Caul Plates and Pressure Intensifiers

Condensation Curing Systems

Residual Curing Stresses

Exotherm

In-Process Cure Monitoring

Cure Modeling

Summary

References


Chapter 7 - The Interaction of Chemical Composition and Processing on Laminate Quality

Prepreg Physical Properties

Chemical Properties

Thermal Properties

Rheological Properties

Laminate Evaluations

Summary

References


Chapter 8 - Adhesive Bonding and Integrally Cocured Structures

Adhesive Bonding

Advantages of Adhesive Bonding

Disadvantages of Adhesive Bonding

Theory of Adhesion

Joint Design

Adhesive Testing

Surface Preparation

Epoxy Adhesives

Bonding Procedures

Sandwich Structures

Honeycomb Core

Honeycomb Processing

Balsa Wood

Foam Cores

Syntactic Core

Inspection

Integrally Cocured Structure

Summary

References


Chapter 9 - Liquid Molding

Preform Technology

Fibers

Woven Fabrics

Three-Dimensional Woven Fabrics

Knitted Fabrics

Stitching

Braiding

P4A Process

Random Mat

Preform Advantages

Preform Disadvantages

Integral Structures Made by Textile Processes

Preform Lay-Up

Resin Injection

Curing

RTM Tooling

Resin Transfer Molding Defects

Resin Film Infusion

Vacuum Assisted Resin Transfer Molding

Summary

References


Chapter 10 - Thermoplastic Composites

The Case for Thermoplastic Composites

Thermoplastic Composite Matrices

Product Forms

Consolidation

Thermoforming

Joining

Summary

References


Chapter 11 - Commercial Processes

Lay-Up Processes

Compression Molding

Injection Molding

Structural Reaction Injection Molding

Pultrusion

Summary

References


Chapter 12 - Assembly

Trimming and Machining Operations

General Assembly Considerations

Hole Drilling

Fastener Installation

Sealing

Painting

Summary

References


Chapter 13 - Nondestructive Inspection and Repair

Nondestructive Inspection

Visual Inspection

Ultrasonic Inspection

Portable Equipment

Radiographic Inspection

Thermographic Inspection

Repair

Fill Repairs

Injection Repairs

Bolted Repairs

Bonded Repairs

Summary

References


Appendix A - Metric Conversions

 
 
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