Composite Material Production Methods - Maicros İleri Mühendislik

There are various methods for composite material production. These methods may differ according to the structure and application area of the material. We can give the production methods under 2 main headings as closed moulding method and open moulding method.

Closed Moulding Composite Production Processes

In closed moulding, the reinforcing material and matrix are processed in a vacuum bag or mould. Closed moulding processes are usually automated and require special equipment. Since this method allows the production of large quantities of material, it can be used in large-scale production facilities.

Prepreg (Pre-matrix Impregnated Fibres)

Resin Transfer Moulding (RTM)

Resin Transfer Moulding is often used in the production of parts with complex geometries. In this method, reinforcing fibres are placed in the mould. The matrix material is injected into the mould through a pre-prepared injection system. The matrix material penetrates the reinforcing fibres in the mould and takes the shape of the part by compression. RTM is used in the production of high strength and high quality parts.

Vacuum Infusion

Vacuum infusion method is a closed moulding method that allows the matrix material to penetrate into the reinforcement fibres using vacuum and the part to take the desired shape. In this method, the reinforcing elements are placed in the mould and the matrix material is transferred to the mould under vacuum. Thus, penetration of the matrix into the reinforcement material is ensured. Vacuum infusion method is generally used in the production of large and complex structures.

Compression Moulding

In this method, the reinforcing element and matrix material are placed in the mould and then compressed under appropriate temperature and pressure. This process allows the matrix to penetrate the fibre material and the part to take shape. Compression moulding is generally used in the production of low-cost high-strength materials.

Pultrusion

Pultrusion is the process of placing a polymer material, usually long fibres (such as glass fibre or carbon fibre), in a matrix and then pushing it into a mould to form a continuous profile or part by applying tensile force. This process is widely used in the production of glass fibre reinforced plastics. Pultrusion is a preferred technique for the production of lightweight, durable and low-cost products.

Open Moulding Composite Production Processes

In open moulding, the reinforcing elements and matrix are exposed to an open atmosphere while hardening. Methods such as hand lay-up, spraying and filament winding are included in this group.

Hand Laying Method

This method is the most preferred and cheapest open moulding method due to the minimum number of equipment required. The reinforcement elements are placed in the mould and then the matrix material is impregnated into the reinforcement material with the help of a brush and roller. The application of reinforcing material and matrix continues until the desired thickness of the produced material is reached. This method is generally used in the production of both large and small parts, including boats, storage tanks, bathtubs.

Spraying Method The spraying method is similar to the hand lay-up method. The difference from hand lay-up is that the matrix material is impregnated into the reinforcement material with a spray gun. The reinforcements are placed in the mould and then the matrix is applied with a spray gun. Rolling can be done to remove air bubbles and smooth the surface. In this method, labour intensity is reduced compared to manual lay-up.

Fibre Winding Method

The fibre winding method is based on winding the continuous fibre into a rotating mould after passing through the resin. The winding angle of the continuous fibre determines the mechanical properties of the material. This method is often used in the manufacture of generally hollow and cylindrical products such as chemical and fuel tanks, pipes, pressure vessels and rocket engine casings.

Conclusion

The production methods of composite materials are selected by considering industrial requirements, cost effects and the properties sought in the end product. Each method has its own advantages and disadvantages. However, continuously developing technology and improvements in production processes enable composite materials to become more efficient, durable and environmentally friendly. Therefore, continuous interest and research into the production methods of composite materials will contribute to the emergence of more innovative and effective production methods in the future.