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tape-laying equipment
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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
... processing uses computer controls, the processor must ensure software verification and security. Equipment requiring qualification includes autoclaves, automated tape-laying machines, automated prepreg-cutting machines, drape-forming machines, inkjet-marking machines, and projection ply-locating machines...
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.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 Chapter
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003033
EISBN: 978-1-62708-200-6
... in aerospace and lower performance applications. applications of prepreg resins aramid fibers fabric types fiber forms fiber sizing agents fiber types fiber-reinforced polymeric matrix composites prepreg tape manufacturing processes prepreg tow weave construction THIS ARTICLE addresses...
Abstract
This article addresses the types, properties, forms, and applications of fibers that are available for use in fiber-reinforced polymeric matrix composites, including glass, graphite, carbon, aramid, boron, silicon carbide, ceramic, continuous oxide and discontinuous oxide fibers. It describes the functions, types, and chemical composition of fiber sizing agents. The article discusses the styles, properties, applications, and weaving methods of unidirectional, two-directional and multidirectionally reinforced fabrics. The article also reviews the use of prepreg resins in aerospace and lower performance applications.
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
... in position on the lay-up tool, which is sometimes equipped with vacuum ports to anchor the backings. Plies are oriented to within ±1° using tape-laying heads, or manually, using straight edges, drafting machine dividing heads ( Ref 4 ) or ruled lines on the table ( Ref 4 ). Indexes or polyester film...
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 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 Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003045
EISBN: 978-1-62708-200-6
... distortion or fiber buckling, especially in tape lay-ups, are usually prohibited. Likewise, lay-up practices that result in fiber bridging the radii are not allowed. All radii should be examined for bridging, and the ply should be repositioned to eliminate this before covering with the next ply or performing...
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.a0003418
EISBN: 978-1-62708-195-5
...Abstract 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...
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.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.a0003368
EISBN: 978-1-62708-195-5
... strategy for conquering lay-up costs is to employ computer-controlled tape or tow placement machines. A heating device located at the roll nip, the place where the slit tape or tow meets the surface of the part being built, causes melting of the thermoplastic to a degree sufficient to achieve tacking...
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.a0003392
EISBN: 978-1-62708-195-5
... methods: Wet lay-up, prepreg lay-up, fiber placement, tape lay-up, pultrusion, resin transfer molding (RTM), vacuum- assisted resin transfer molding, filament winding, compression molding, injection molding, centrifugal casting Processing equipment: Vacuum bagging, molds, ovens, autoclaves, presses...
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.
Series: ASM Handbook
Volume: 20
Publisher: ASM International
Published: 01 January 1997
DOI: 10.31399/asm.hb.v20.a0002465
EISBN: 978-1-62708-194-8
... list of current reinforcements, matrix materials, and coupling agents. Most frequently used reinforcements include: Uniaxial continuous fiber for end-tape filament winding, braiding, or pultrusion Fabric (warp and fill continuous fiber) for tape wrapping and lay-up fabrication processes...
Abstract
This article describes the interaction of composition, manufacturing process, and composite properties of composites. The manufacturing process includes resin-matrix, metal-matrix, and carbon/carbon matrix processing. The article discusses various mechanical properties of composites. It explores how variations in the composition, manufacturing, shop process instructions, and loading/environmental conditions can affect the use of a composite product in a performance/service life operation.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003414
EISBN: 978-1-62708-195-5
... expensive, and for RTM, tooling will be most expensive. Ancillary Materials Hand lay-up and spray- up do not really require ancillary materials, but vacuum infusion does involve a foil, sealant tape, tubes, and hoses. The same applies to the prepregging technologies where foils, peel ply, and bleeder...
Abstract
Vacuum infusion is a resin injection technique derived from resin transfer molding. This article discusses the characteristics of the technique and its applications. It presents the theory and background of the technique and provides an illustration of how parts are made. The article provides information on the equipment and material used for vacuum infusion. It describes the mechanical properties of components and summarizes the influence of production on the properties. The article concludes with a discussion on design guidelines.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003447
EISBN: 978-1-62708-195-5
... component applications are either filament- wound fiber bundles or tows, unidirectional fiber tape laydown (tape wrapped), woven fabric, chopped fiber molding compound, or lay-up fabrics that are all either combined with a staged (partially cured) liquid resin or impregnated with a wet resin during...
Abstract
This article discusses the materials and properties of polymer-matrix composites to characterize each generic material according to its composition and method of manufacture. It contains a table that lists the key physical, mechanical, thermal, and electrical properties, and in-service conditions of concern for resin-matrix composites. Axes definitions, symbols, and special property calculations for composite material property tests are reviewed. The article provides an overview of the performance capabilities of selected polymer-matrix composite materials such as thermoplastic-matrix composites and thermoset-matrix composites. The thermoplastic-matrix composites include thermoplastic polyester resins and fiber resin composites; thermoplastic polyamide resins and fiber-resin composites; and thermoplastic polysulfone resins and fiber-resin composites.
Series: ASM Handbook
Volume: 6A
Publisher: ASM International
Published: 31 October 2011
DOI: 10.31399/asm.hb.v06a.a0005605
EISBN: 978-1-62708-174-0
... that are capable of dealing with an increasing range of materials. Equipment and Procedures Two types of UAM systems for fabrication of parts are shown in Fig. 3 . The system in Fig. 3 features a moving UAM gantry with a stationary base plate and integrated tape laying, tape cutting, and CNC machining...
Abstract
The ultrasonic additive manufacturing (UAM) process consists of building up solid metal objects by ultrasonically welding successive layers of metal tape into a three-dimensional shape with periodic machining operations to create detailed features of the resultant object. This article provides information on the materials, welding parameters, process consumables, procedures, and applications of the UAM. It describes the methods for determining metallurgical and mechanical properties of solid metal parts to assess the range of materials and applications for which the process is suited. These methods include peel testing, push-pin testing, and microhardness/nanohardness testing. The article also reviews the issues to be addressed in maintaining UAM fabrication quality.
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.a0003451
EISBN: 978-1-62708-195-5
... too large, the part may be beyond economical repair. The larger the repair, the longer the delay that will be incurred in completing it. The types of repair include: Wet lay-up liquid resins (cold or warm-cured) are available. Hot-cured, preimpregnated fabrics or tapes (prepreg...
Book Chapter
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003412
EISBN: 978-1-62708-195-5
... neoprene cork pressure-sensitive tape, silicone rubber, or Teflon or metal bars. Dam height should be approximately the same as the lay-up thickness, including release and bleeder plies, to prevent rounding off of the part edge by the action of the vacuum bag. Vacuum Bag The vacuum bag is used...
Abstract
Curing is the irreversible change in the physical properties of a thermosetting resin brought about by a chemical reaction, condensation, ring closure, or addition. This article discusses the material types and functions of various components considered in the preparation for curing. It presents a discussion on the major elements of an autoclave system, namely, pressure vessel, gas stream heating and circulation sources, gas stream pressurizing systems, loading systems, and vacuum systems. The article describes a computerized approach to the simultaneous control of materials reaction behavior and consolidation dynamics, using an autoclave as the reaction vessel.
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.
Book Chapter
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003039
EISBN: 978-1-62708-200-6
... of Westinghouse Electric Company, Marine Division Thermoset resins, generally used as binders for reinforcements, can be applied to the dry roving at the time of winding, which is known as wet winding. They may also be applied prior to winding as a tow or tape prepreg and used promptly or refrigerated...
Abstract
Filament winding is a process that allows the precise lay-down of continuous reinforcement in predescribed patterns at a high rate of speed. This article discusses the filament winding process and includes a comparison to other compacting and curing processes. The article describes design factors, and techniques to produce aerodynamic surfaces, improve surface smoothness, and avoid slipping and bridging of filament. The article discusses tooling and the equipment used in the filament winding process, namely, mandrel design, winding machines, tensioners, and ovens.