Processing of composites and polymers

What is a Composite?
1. A composite is a multi-phase material that exhibits a significant
proportion of the properties of both constituent phases such that
a better combination of properties is realized.
Better property combinations are fashioned by judicious
combination of two or more distinct materials.
2. A composite is artificially made, as opposed to one that occurs or
forms naturally. In addition, the constituent phases must be
chemically dissimilar and separated by a distinct interface.
a. Multi-phase alloys (as Pearlite, combination of α Ferrite &
Cementite) are composites?
b. Wood is a natural composite (core is covered by cellulose)
c. Bone is a natural composite (protein collagen and mineral
apatite)
Do a, b, c fit to definition of composites???
 Why Need Composites?
Many of our modern technologies require materials with unusual
combinations of properties that can not be met by conventional
metal alloys, ceramics and polymeric materials. This is especially
true for aerospace, underwater and transportation applications.
For example, aircraft engineers are increasingly searching for
structural materials that have low densities, are strong, stiff, and
abrasion and impact resistant, and are not easily corroded.
This is a rather difficult combination of characteristics.
Frequently, strong materials are relatively dense.
Also, increasing the strength or stiffness generally results in a
decrease in impact strength (& ductility).
This is why, we need to engineer new materials, called
composites, by combining various existing ones.
 Carbon-Carbon Composites Ceramic-Matrix Composites

Carbon fibers in Carbon matrix (One of the most advanced composites)

Processing of C-C Composites
- Initial processing is similar to CFRP composites.
- Long C fibers are laid in desired 2D/3D pattern.
- This pattern is impregnated with Polymer resin (Phenol), making it CFRPC
- To convert CFRPC into C-C composite, heating is done (Pyrolysis) to drive off
molecular O2, H2 & N2.
- After this, heat treatments at high temperatures cause C matrix to densify
and increase in strength
- The resulting matrix will consist of only C
Applications:
The carbon–carbon composites are employed in
- Rocket motors
- As friction materials in aircraft and high-performance automobiles
- For hot-pressing molds
- In components for advanced turbine engines,
- As ablative shields for re-entry vehicles.
 Processing of Continuous FRC
To fabricate continuous fiber-reinforced plastics that meet design specifications
- the fibers should be uniformly distributed within the plastic matrix and,
- in most instances, all oriented in virtually the same direction.
- Important manufacturing processes for Continuous FRC are:
- Pultrusion
- Pre-preg production processes
- Filament winding
1. Pultrusion:
• Pultrusion is used for the manufacture of components having continuous
lengths and a constant cross-sectional shape (i.e., rods, tubes, beams, etc.)
Fibers of glass,
carbon & aramid Polyester, Vinyl
ester & Epoxy

- Continuous process
- Easily automated
- High production rate -machined die to
-Controls
- Cost effective impart final
fiber/resin ratio
- Wide variety of shapes - Resin ranges b/w shape on FRC
- No practical limit on 40 & 70% Vol - Die is heated to
length of part cure the FRC
 Pultrusion Process
Continuous fiber roving's are dipped into a resin bath and
pulled through a shaping die where the impregnated resin
cures

• The sections produced are

reinforced throughout their length
by continuous fibers
• Like extrusion, the pieces have a
constant cross section, whose profile
is determined by the shape of the
die opening
• The cured product is cut into long
straight sections
EMU
Pultrusion Process
Pre-Preg Production Process
 Processing of Continuous FRC
2. Pre-preg Production Processes
Prepreg is the composite industry’s term for continuous fiber reinforcement
pre-impregnated with a polymer resin that is only partially cured. This material
is delivered in tape form to the manufacturer, who then directly molds and fully
cures the product without having to add any resin. It is probably the composite
material form most widely used for structural applications
Calendering: The fibers are sandwiched and pressed between sheets of release and carrier
paper using heated rollers
- Typical Pre-peg tape thickness ranges Used to spread
between 0.08 and 0.25 mm a thin film of
- Tape widths range between 25 and polymer resin on
release paper
1525 mm
- Resin content lies between about 35
and 45 vol%
At room temperature the thermoset matrix
undergoes curing reactions; therefore,
the prepreg is stored at 0C or lower.
Also, the time in use at room temperature
(or “out-time”) must be minimized. If properly
handled, thermoset prepregs have a lifetime of
at least six months or usually longer.
Manufacturing Lay Ups
 Processing of Continuous FRC
2. Pre-preg Production Processes
• Both thermoplastic and thermosetting resins are utilized; as matrix
• Carbon, glass, and aramid fibers are the common fiber reinforcements.
Fabrication of Final Product Using Pre-peg
- Actual fabrication begins with the “lay-up”: pre-peg sheets are piled up to
make desired thickness, after removing carrier paper
- The lay-up arrangement can be uni-directional. But often they are stacked in
different orientation to make a cross ply or angle ply
- Final curing is accomplished by simultaneous application of heat and
pressure

- Lay-up can be done with hand, in which sheets are cut and positioned on
tool by hand. Alternatively ply pattern can be cut with machine also and
positioned with hand
- Lay up Process can be automated also (as filament winding) to reduce
product cost.
 Processing of Continuous FRC
3. Filament Winding
- Filament winding is a process by which continuous reinforcing fibers are
accurately positioned in a predetermined pattern to form a hollow (usually
cylindrical) shape.
- The fibers, either as individual strands or as tows, are first fed through a
resin bath and then are continuously wound onto a mandrel, usually using
automated winding equipment.
- After the appropriate number of layers have been applied, curing is carried
out either in an oven or at room temperature, after which the mandrel is
removed.
- As an alternative, narrow and thin prepregs (i.e., tow pregs) 10 mm or less in
width may be filament wound.
Filament Winding
Filament Winding
 Processing of Continuous FRC
3. Filament Winding Techniques

Applications:
- Filament-wound parts have very high
strength-to-weight ratios.
- Rocket motor casings, storage tanks
and pipes, and pressure vessels.
- I-beams.
- This technology is advancing very
rapidly because it is very cost
effective.
Polymer: definition
 A polymer is a compound consisting of long-
chain molecules, each molecule is made up of
repeating units connected together.
 There may be thousands or even millions of units
in a single molecule.
 Most polymers are based on carbon molecules and
are therefore considered as organic molecules.
 Video 1
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Process of forming a continuous piece of plastic by

forcing it through a shaping orifice with or without the
presence of heat. The opening through which the resins
are forced gives the product its form, resulting in
consistent thickness and gauge control.

PLASTIC EXTRUSION
Types of Extrusions
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 Sheet Extrusion
 Profile Extrusion
 Pipe extrusion
 Blown Film Extrusion
 Cast Film Extrusion
Extrusion process
Sheet Extrusion
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Sheet products plastic is sheet

extruded like shown in the left Sheet extrusion machine
and automatically cut to smaller
sheets for using in different
fields
Sheet Extrusion
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 Sheet extrusion is a technique for making flat plastic

sheets from a variety of resins. The thinner gauges are
thermoformed into packaging applications such as
drink cups, deli containers, produce trays, baby wipe
containers and margarine tubs. Another market
segment uses thick sheet for industrial and recreational
applications like truck bed liners, pallets, automotive
dun age, playground equipment and boats. The third
primary use for extruded sheet is in geomembranes,
where flat sheet is welded into large containment
systems for mining applications and municipal waste
disposal.
 Video 2

Profile Extrusion
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extrusion profile variety by

using specific formed mold you Profile extrusion machine
get different forms like window
frame
Profile Extrusion
23 Rubber Profile Extrusion is accomplished by
forcing uncured rubber through a die, under
heat and pressure, to form a part with a
uniform cross section. This uncured rubber is
then run through a heating unit to initiate the
chemical cross linking reaction that causes the
rubber to cure.
 Video 3

Pipe extrusion
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Pipe
extrusion
machine

PE coiling pipe
production line
with large
caliber

We can have some texture in the outer surface by using

textured molds ,the air flows through the mold during
extrusion process not to have it stuck together
Pipe extrusion
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 Pipe extrusion is defined as a process of
forcing the polymer melt through a shaping
die (in this case: circular). The extrudate from
the die is sized, cooled and the formed pipe is
pulled to the winder or a cut off device with
the aid of haul off device.
 Video 4

Blown Film Extrusion

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blown film blown film machine

Application Blown Film Blown Film & Flexible

Packaging
Blown Film Extrusion
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 In film blowing, a tubular cross-section is
extruded through an annular die (usually a
spiral die) and is drawn and inflated until the
frost line is reached. The extruded tubular
profile passes through one or two air rings to
cool the material.
Cast Film Extrusion
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cast blown film

Cast film machine

Hand wrap small blown film

Cast Film Extrusion
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 The cast film process differs from the blown

film process through the fast quench and
virtual unidirectional orientation capabilities.
These characteristics allow a cast film line to
operate at higher production rates while
producing amazing optics. Applications in
food and retail packaging take advantage of
these strengths.
 Rotational Molding
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 Rotational molding (or Rot molding) is a method that
involves the slow tumbling, heating, and melting of a
thermoplastic powder in a biaxial rotating mold to produce
seamless, hollow plastic parts. This process is typically
used to mold hollow parts, especially those with complex
and varied shapes not easily obtainable by other hollow-art
processes. It is a virtually shear-free and pressure-free
process. The wall thickness uniformity and part weight can
be easily maintained. There is very little waste of material
due to scrap. Rot molding molds are often less expensive
than other types of molds.
Process Steps
Step 2. Heating and fusion of resin
 Step #1. Loading resin into
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the mold

The rotomolding process is begun by placing The mold is rotated within the oven
a pre-measured amount of plastic material until all the plastic material has been
(in either liquid or powder form) in a cavity. picked up by the hot inside surfaces
The mold is then closed and indexed into an of the cavity and densifies into a
oven where it and its contents are brought uniform layer. While continuing the
up to the molding temperature. As the mold rotation, the machine moves the
is heated, it is rotated continuously about its mold out of the oven and into the
vertical and horizontal axes. This biaxial cooling chamber.
rotation brings all surfaces of the mold in
contact with the plastic material.
Step 3. Cooling before unloading
Step 4. Unloading/Demoulding

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Air, or a mixture of air and water, cools the When the polymer has cooled
mold and the layers of molten plastic sufficiently to retain its shape and be
material. This cooling process continues easily handled, the mould is opened
until the part has cooled sufficiently to and the product removed. At this
retain its shape. The machine then indexes point powder can once again be
the mold to the loading and unloading placed in the mould and the cycle
station. repeated.
Rotational Molding
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Advantages:
 Very large parts can be manufactured

 Chemical waste and storage tanks up to 2,500

gallons
 Minimum design constraints

 Very low tooling costs

 No polymer weld lines

 Stress-free products
Vacuum Forming
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 Vacuum forming is a plastic thermoforming process that

involves forming thermoplastic sheets into three-
dimensional shapes through the application of heat and
pressure. In general terms, vacuum forming refers to all
sheet forming methods, including drape forming, which is
one of the most popular. Basically during vacuum forming
processes, plastic material is heated until it becomes
pliable, and then it is placed over a mold and drawn in by a
vacuum until it takes on the desired shape. Vacuum
thermoforming is a great method for producing plastic parts
that have sharp details and fit nicely to specific products.
Vacuum Forming
 During the vacuum forming process, a sheet of heated plastic
35 material is placed over a male or female mold. The mold then moves
towards the sheet and presses against it to create a seal. Next, the
application of a vacuum draws out the air between the mold and the
sheet so that the plastic conforms to the mold exactly. This is
accomplished through venting holes in the mold that are joined to
vacuum lines. The mold also has a water cooling system integrated
into it that brings the temperature of the plastic to the set
temperature needed. When the curing temperature is reached and the
piece is formed, air blows back into the mold and separates the new
part from the mold.
Vacuum Forming

Advantages
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 Economical for small to medium production

runs
 Low tooling costs

 Quick startup

 High strength to weight ratio

 Efficient prototyping

 No need for painting; the color and texture are

formed in
BLOW MOULDING
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 WHAT IS BLOW MOULDING?
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 The basic process of this method includes 6 steps:
 1) A thermoplastic resin is heated to a molten state
 2)It is then extruded through a die head to form a hollow tube
called a parison.
 3)The parison is dropped between two mold halves, which
close around it.
 4)The parison is inflated.
 5)The plastic solidifies as it is cooled inside the mold.
 6)The mold opens and the finished component is removed.
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blow molding machine

 There are basically four types of blow molding
used in the production of plastic bottles, jugs and
jars. These four types are:
 Extrusion blow molding
 Injection blow molding
 Stretch blow molding
 Reheat and blow molding.

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 Extrusion blow molding is
perhaps the simplest type of blow
molding. A hot tube of plastic
material is dropped from an
extruder and captured in a water
cooled mold. Once the molds are
closed, air is injected through the
top or the neck of the container;
just as if one were blowing up a
balloon. When the hot plastic
material is blown up and touches
the walls of the mold the material
"freezes" and the container now
maintains its rigid
shape.eg:detergent and chemical
bottles

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 HDPE AND PP MATERİAL - BLOW MOULDING

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 Injection blow molding is part injection molding
and part blow molding. With injection blow molding,
the hot plastic material is first injected into a cavity
where it encircles the blow stem, which is used to
create the neck and establish the gram weight.(a)
 The injected material is then carried to the next
station on the machine, where it is blown up into the
finished container as in the extrusion blow molding
process above. (b)
 Injection blow molding is generally suitable for
smaller containers and absolutely no handleware.

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 Extrusion blow molds are
generally much less expensive
than injection blow molds and
can be produced in a much
shorter period of time.
 Extrusion method is used to
make items such as commercial
drums and milk bottles.
 Injection method is used to make
carbonated soft drink bottles.

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 Stretch blow molding is perhaps best known for
producing P.E.T. bottles commonly used for water, juice
and a variety of other products.
 In plastic soda bottle manufacture, the plastic—
polyethylene terephthalate (PET)—is first polymerized,
which involves creating long strings of molecules. Once
the plastic is prepared, it undergoes stretch blow molding.
In this process, a long tube (parison) of PET is put into a
mold, and a steel rod (mandrel) is inserted into it.
 Next, highly pressurized air shoots through the mandrel
and forces the parison against the walls of the mold. A
separate bottom piece is inserted into the mold to shape
the bottle so that it can stand on a flat surface.

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 PET BOTTLES - STRECH BLOW MOULDING

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 The reheat and blow
molding process (RHB) is
a type of stretch blow
process. This stretching
helps to increase the impact
resistance of the container
and also helps to produce a
very thin walled container.

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 INJECTION MOULDING

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WHAT IS INJECTION MOULDING ?
 Injection Molding is the technique of injecting molten
plastic into a cold mold and forming a part. It consists of a
hopper that holds the raw plastic pellets.
 The hopper feeds the barrel with the plastic. The plastic is
melted in the barrel and with the help of the screw (piston)
is injected into a mold.
 The mold being colder than the plastic rapidly cools and
solidifies the plastic.
 The mold is then opened and the part is ejected out of the
mold.
 Injection moulding is the process of choice for producing
precision parts in medium to high volume.

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PROCESS

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Some Typical Complications:
 Burned or Scorched Parts: Melt temperature may be too
high. Polymer may be becoming trapped and degrading in the
injection nozzle. Cycle time may be too long allowing the
resin to overheat.
 Warpage of Parts: Uneven surface temperature of the
molds. Non-uniform wall thickness of mold design.
 Surface Imperfections: Melt temperature may be too high
causing resin decomposition and gas evolution (bubbles).
Excessive moisture in the resin. Low pressure causing
incomplete filling of mold.
 Incomplete Cavity Filling: Injection stroke may be too
small for mold (ie. not enough resin is being injected).
Injection speed may be too slow causing freezing before mold
is filled.

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APPLICATIONS:

 Injection moulding is applied to many types of plastic

such as pp, pet, hdpe, ldpe, polystyrene, abs etc.

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