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David L. Bourell, Joseph J. Beaman, Jr., Donald Klosterman, Ian Gibson, Amit Bandyopadhyay
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automated tape laying
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Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003411
EISBN: 978-1-62708-195-5
...Abstract Abstract Automated tape laying is a mature process used in both commercial and military aircraft applications. This article provides a brief history of the process and describes the use of commercially available flat and contour tape-laying equipment. It discusses the advantages...
Abstract
Automated tape laying is a mature process used in both commercial and military aircraft applications. This article provides a brief history of the process and describes the use of commercially available flat and contour tape-laying equipment. It discusses the advantages and disadvantages of the tape laying. The article describes the various components of a ten-axis gantry-type tape laying machine and the tape laying process. It provides a discussion on typical material types and forms for tape laying and provides information on design guidelines for tape laying.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003434
EISBN: 978-1-62708-195-5
.... It concludes with a discussion on automated tape laying and fiber placement, as well as the numerically aided lay-up process. in-process inspection composite materials lay-up material control quality control automated tape laying fiber placement numerically aided lay-up IN-PROCESS INSPECTION...
Abstract
In-process inspection during composite material lay-up is essential if the structural, dimensional, and environmental performance designed into a part is to be consistently achieved. This article discusses the requirements to be met by the facilities and equipment to produce high-quality composites. It reviews the procedures that are allowed and prohibited in controlled-contamination areas of lay-up. The article emphasizes significant areas, such as material control and lay-up process, in which quality-control personnel can be effective in preventing production problems. It concludes with a discussion on automated tape laying and fiber placement, as well as the numerically aided lay-up process.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003410
EISBN: 978-1-62708-195-5
... areas of missing tows. fiber placement FIBER PLACEMENT is a unique process combining the differential tow payout capability of filament winding and the compaction and cut-restart capabilities of automated tape laying. During the fiber placement process, individual prepreg fibers, called tows...
Abstract
This article schematically illustrates a fiber placement system and provides information on the applications of fiber placement. It discusses materials and design considerations for fiber placement. The article provides information on techniques that can be used to eliminate areas of missing tows.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003419
EISBN: 978-1-62708-195-5
... of many manufacturing operations. However, there are also automated means to layup thermoplastic prepreg tapes. Equipment conceptually similar to that used for automated layup of thermoset prepreg tapes (see the article “Automated Tape Laying” in this Section) may also be used to layup thermoplastic...
Abstract
This article describes the characteristics of thermoplastic composites and its material forms. It presents the steps and considerations in manufacturing the thermoplastic composites. The article describes the various techniques of manufacturing, such as consolidation, autoclave molding, diaphragm forming, compression molding, roll forming, bladder molding, liquid molding, filament winding, and pultrusion.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003409
EISBN: 978-1-62708-195-5
...- niche applications. Unidirectional tape lay-up is better suited to automated tape layers that can rapidly cut and deposit material, provided the lay-up is flat enough (see the article “Automated Tape Laying” in this Volume). Recently, thicker unidirectional tape prepreg has been qualified for aircraft...
Abstract
The prepreg hand lay-up process is a versatile, reliable, cost-effective, and high quality process for fabricating large or small components. This article discusses the technique characteristics and applications of the process. It describes the stages involved in the process of lay-up, namely, lay-up definition, ply-kit cutting, layup, debulking, and preparation for curing. The article concludes with a discussion on the component properties and design guidelines of the prepreg hand lay-up process.
Book Chapter
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003397
EISBN: 978-1-62708-195-5
... in the aerospace industry (see the article “Automated Tape Laying” in this Volume). However, compared to ATP, the cost and ease of use of LOM machine is favorable for production of small (e.g., 60 by 30 by 15 cm, or 24 by 12 by 6 in.) articles. Thus, with regards to PMCs, LOM holds the most short-term potential...
Abstract
This article reviews various rapid prototyping (RP) processes such as stereolithography, powder sintering, hot melt extrusion, sheet lamination, solid ground curing, and three-dimensional printing. It discusses the various material prototypes produced by RP technology. The list of materials includes particulate and fiber-reinforced polymers, ceramic-matrix composites, and metal-matrix composites. The article also provides information on freeform-fabrication techniques for composite part lay-up.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003392
EISBN: 978-1-62708-195-5
.... The complex equipment for filament winding, automated tape lay-up, RTM, and press, oven, and autoclave curing can become exponentially more expensive as individual components increase in size. Consideration must be given to residual stresses created in materials as they cool from elevated cure temperature...
Abstract
This article describes common design criteria and identifies the design considerations that have a significant effect on the end product. The design criteria include cost, size, mechanical properties, repeatability and precision of parts, damage tolerance and durability, and environmental constraints.
Book Chapter
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003360
EISBN: 978-1-62708-195-5
...; multidirectionally reinforced fabrics; hybrid fabrics; woven fabric prepregs; unidirectional and multidirectional tape prepregs; and the prepreg tow. The article discusses three major categories of tape manufacturing processes, namely, the hand lay-up, machine-cut patterns that are laid up by hand, and the automatic...
Abstract
This article describes the types of fabrics and preforms used in the manufacture of advanced composites and related selection, design, manufacturing, and performance considerations. The types of fabrics and preforms include unidirectional and two-directional fabrics; multidirectionally reinforced fabrics; hybrid fabrics; woven fabric prepregs; unidirectional and multidirectional tape prepregs; and the prepreg tow. The article discusses three major categories of tape manufacturing processes, namely, the hand lay-up, machine-cut patterns that are laid up by hand, and the automatic machine lay-up. It provides a description of the two classes of prepregs. These include those that are suitable for high-performance applications and suitable for lower-performance molding compounds.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003395
EISBN: 978-1-62708-195-5
... of automated tape laying and fiber placement, significant programming and capital investment. Mixing the reinforcement with the resin system in situ during the fabrication process allows for three-dimensional reinforcements or continuous processing while increasing material utilization. In wet filament...
Abstract
Designing composites for structural performance initially involves meeting a set of desired performance specifications at a minimum cost. This article discusses the factors that are considered in designing the manufacturing of polymeric composites. It describes the various aspects of manufacturing, forming process, and post-processing and fabrication for designing the composites.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003477
EISBN: 978-1-62708-195-5
.... Fig. 20 Materials use in the Typhoon (Eurofighter) airplane The skins of the wing ( Fig. 21 ) are solid laminate, with thicknesses varying from root to tip between about 20 and 4 mm (0.8 and 0.16 in.). They are laminated by automated tape laying. During manufacturing, the wing skins are cured...
Abstract
This article provides information on the applications of fiber-reinforced composites in commercial and military aircrafts. It tabulates the composite components in various types of aircraft. The applications of the composites in the components of Boeing 727, 737, 757, 767, 777, and 777-200 are schematically illustrated.
Book Chapter
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003036
EISBN: 978-1-62708-200-6
... process and a fully automated manufacturing sequence. Lay-up system design is determined by material form, part shape, production requirements, and costs. The processes of die, ultrasonic, and computer-controlled ply cutting; flat and contoured tape laying; ply handling; and automated ply lamination...
Abstract
Wet lay-up using hand or spray techniques is one of the simplest methods of combining a fiber reinforcement with a solidifying resin to form a composite structure. This article describes several wet lay-up processes - including contact molding, spray molding, vacuum bag molding, and autoclave molding - suited for making parts on open-faced molds using polyester and vinyl ester resins. The article also provides information on mechanically assisted lay-up which can be automated to alleviate some of the manual work.
Series: ASM Handbook
Volume: 9
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.hb.v09.a0009071
EISBN: 978-1-62708-177-1
... of prepreg materials, automated tape lay-up of prepreg materials, resin transfer molding, vacuum-assisted resin transfer molding, resin film infusion, wet lay-up, filament winding, pultrusion, and compression molding of sheet molding or bulk molding compound. While these processes are general in description...
Abstract
This article illustrates the polymer matrices used for composite materials. It describes the use of prepeg materials in manufacturing high-performance composites. The article discusses the various infusion processes for the development of fiber-reinforced composites, namely, resin transfer molding, vacuum-assisted resin transfer molding, and resin film infusion. It explains the composite- and matrix-toughening methods for fiber-reinforced composites, such as dispersed-phase toughening and interlayer toughening. The article concludes with information on optical microscopy, which provides an insight into the micro- and macrostructure of fiber-reinforced composites.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003425
EISBN: 978-1-62708-195-5
... or with automated equipment (i.e., contoured tape lay-up machines or fiber placement machines). Individual full plies and partial padup plies (typically 0.14–0.30 mm, or 0.005–0.01 in., thick each) are sequentially placed on a shaped tool and vacuum compacted every 1 to 3 plies to reduce bulking. Once a layup...
Abstract
Advanced thermoplastic composites possess impact resistance, fracture toughness, and elevated temperature endurance properties due to their melt-fusible nature. This article presents the material options available for thermoplastic composites such as pseudothermoplastics, post-impregnated thermoplastics, and true thermoplastics. It describes the processing methods of thermoplastic composites, including weaving, seaming, autoclaving, preconsolidation, roll consolidation, roll forming/pultruding, thermoforming, press forming, hydroforming, and diaphragm forming. The article provides information on different types of joints, namely, fastened, adhesive bonded, dual polymer bonded, co-consolidated, and welded joints. It explains the joining methods of thermoplastic composites, such as press forming, diaphragm forming, autoclaving, ultrasonic welding, resistance welding, and induction welding.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003418
EISBN: 978-1-62708-195-5
..., a tube can be wrapped in one operation. When making thick-walled tubing or when using materials with a high bulk factor, it is desirable to wrap the tube in multiple wrap increments, debulking in between wraps by applying and removing shrink tape on automated tape wrapping machines with consistent tape...
Abstract
This article describes processes and equipment that are used to produce composite tubular parts. The processes include sheeting, pattern cutting, tube rolling, shrink tape debulking, and finishing. The article provides a discussion on materials that are most suitable for tube rolling: preimpregnated materials and unidirectional tapes. The article also discusses wrapping techniques of cylindrical and tapered tubes, such as convolute and spiral wrapping.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003368
EISBN: 978-1-62708-195-5
... costs can be reduced 20 to 35% by use of automated material-placement machines. With thermoplastics, though, total savings from hot tape lay-up will be larger than with thermosets because compaction occurs during lay-up, and autoclave cure is not required. Generally, production volumes must...
Abstract
This article provides information on the thermoplastic resins used as matrix materials for continuous fiber reinforced composites. It focuses on the materials that are suitable for fabrication of structural laminates and used for aerospace applications. The article provides a discussion on the background, categories, characteristics, product forms, properties, cost benefits, and processing techniques of thermoplastic resins. Strategies that have been advanced to deal with impregnation difficulties are also discussed.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003416
EISBN: 978-1-62708-195-5
... (from part to part and from layer to layer). The accuracy can be superior to that of fiber placement and automated tape-laying machines. The capacity to use continuous fibers over the whole component area (without joints) and to orient fibers easily in the load direction. This simplifies...
Abstract
Filament winding is a process for fabricating a composite structure in which continuous reinforcements, either previously impregnated with a matrix material or impregnated during winding, is placed over a rotating form or mandrel in a prescribed way to meet certain stress conditions. This article describes the advancements in filament winding and lists the advantages and disadvantages of filament winding. It discusses the effects of fiber tension in filament winding and the selection of fibers, resins, and materials for filament winding. The article emphasizes the three basic filament-winding patterns, such as helical, polar, and hoop. It presents information on the applications of filament winding, including rocket motors, natural gas vehicle (NGV) tanks, and sporting goods. The article presents recommendations for the basic design guidelines for filament-winding design/manufacturing process and concludes with a discussion on fabrication recommendations.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003394
EISBN: 978-1-62708-195-5
.... Fig. 12 Finite-element mesh (left) and resin flow-front simulation (right) for resin transfer molding injection Fiber Placement and Tape-Laying Interfaces Fiber-placement machines combine the advantages of filament winding, contour tape laying, and computer control to automate...
Abstract
Continuous fiber composite materials offer dramatic opportunities for producing lightweight laminates with tremendous performance capabilities. This article describes the kinematics of fabric deformation and explains the algorithms used in draping simulation. It discusses the basic components, such as laminate and ply, of continuous fiber composite. The article provides information on the core sample and ply analysis. It details producibility, flat-pattern evaluations, and laminate surface offset. The article discusses various interfaces, such as the structural analysis interface, the resin transfer molding interface, the fiber placement and tape-laying interface, and the laser projection interface.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003426
EISBN: 978-1-62708-195-5
... can keep weight to a minimum. Also unidirectional fiber materials typically have less waste than woven products, unidirectional products lend themselves to automated lay-up in tape-laying machines, and unidirectional products may provide a smoother aerodynamic external surface than woven products...
Abstract
Good hole-drilling processes are key to joining composite parts with other composite parts or with metal parts. This article discusses the considerations for drilling polymer-matrix composites. It describes the use of power-feed drill motors and automated drilling/fastener installation equipment. The article provides a discussion on reaming, countersinking, and three recommended choices of cutting tools for producing a countersink in carbon/epoxy structure. The cutting tools include: standard carbide insert cutters, solid carbide cutters, or polycrystalline diamond (PCD) insert cutters. The article concludes with a discussion on inspection of hole quality.
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003045
EISBN: 978-1-62708-200-6
... risking damage and distortion of all plies in the lay-up. The inspector must be on site to verify the work as it is performed during these critical operations. This is even true for automated lay-up operations. Not only angles, but overlap and gap tolerance between segments of tape must also be verified...
Abstract
Ultrasonic inspection is a nondestructive technique that is useful in both quality control and research applications for flaw detection in fiber-reinforced composite materials. This article describes ultrasonic nondestructive analysis by outlining its three basic types of scans. It reviews the important quality control techniques used during the manufacture of composite components by analyzing tooling control, material control, pattern orientation control, and in-process control.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003401
EISBN: 978-1-62708-195-5
... covered in the present edition also were described in the 1987 edition, some techniques now covered are new (vacuum infusion and several thermoplastic techniques), and a couple that previously were reported as representing recent developments are now well established (fiber placement and tape laying...
Abstract
This article explains the key features of the manufacturing techniques for polymer composites. It describes the selection of a technically and economically feasible manufacturing technique for a composite design. The article discusses widely accepted and emerging techniques to manufacture polymer composites such as open-mold techniques.