EnglishFrenchGermanJapanesePortugueseSpanish

The CKN Knowledge in Practice Centre is in the early stages of content creation and currently focuses on the theme of thermal management.
We appreciate any feedback or content suggestions/requests using the links below

Content requests General feedback Feedback on this page

  • Home
  • Introduction to Composites
    • Fundamentals of composite materials
      • How Composites Differ From Metals
      • When to Use Composites
      • Composites design
      • Composites manufacturing
    • Systems approach to composite materials
  • Foundational Knowledge
    • Materials science
      • Material structure
        • Polymer (matrix) structure
          • Thermoplastic polymers
          • Thermoset polymers
      • Material properties
        • Basic Definitions of Material Properties
          • Thermal conductivity
          • Specific heat capacity
          • Thermal diffusivity
        • Polymer properties
          • Heat of reaction
          • Degree of cure
          • Outgassing of Polymer Resins
          • Viscosity (resin)
          • Glass transition temperature (Tg)
        • Reinforcement properties
        • Composite properties
          • Fatigue Limits
          • Failure Theories
          • Safety Factors
          • Macro-Mechanics
          • Micro-Mechanics
    • Processing science
      • Thermal behaviour
        • Heat transfer
          • Conduction
          • Convection
        • Thermal phase transitions of polymers
        • Cure of thermosetting polymers
    • Foundational method documents
      • How to measure curing time and degree of cure
      • How to measure gel time
      • How to measure reinforcement content (and corresponding matrix content)
      • Tensile Testing
  • Systems Knowledge
    • System parameters - inputs and outcomes
    • System interactions
    • Thermal and cure/crystallization management (TM)
      • Effect of material in a thermal management system
      • Effect of shape in a thermal management system
      • Effect of tooling in a thermal management system
      • Effect of equipment in a thermal management system
    • Materials deposition and consolidation management (MDCM)
    • Residual stress and dimensional control management (RSDM)
      • Effect of material in a RSDM system
      • Effect of shape in a RSDM system
      • Effect of tooling in a RSDM system
      • Effect of equipment in a RSDM system
    • Machining and assembly management (MAM)
    • Quality/inspection management (QIM)
    • Systems knowledge method documents
      • How to perform an experimental thermal profile
  • Systems Catalogue
    • The factory
      • Factory layout (where)
      • Objects in the factory (what)
        • Material
          • Cores & inserts
            • Foam
            • Honeycomb
          • Prepreg
          • Matrix
            • Fire Retardant Resins/Additives
            • Epoxy resin
            • Polyester resin
        • Shape
        • Tooling and consumables
        • Equipment
          • Autoclave
          • Room temperature transformation
          • Hot press
          • Oven
      • Factory cells (where and how)
        • Testing
          • Thermomechanical Analyzer (TMA)
        • Material deposition
          • Automated fibre placement (AFP)
          • Compression moulding
          • Filament winding
          • Hand layup prepreg (Autoclave/Out-of-autoclave) processing
          • Vacuum assisted resin transfer moulding (VARTM)/resin infusion (VARI)
          • Wet layup
        • Thermal transformation
    • Resources
      • Composites Courses at Canadian HEI
  • Practice
    • Integrated Product Development
      • Practice for Developing a Product
        • Composite Production Part Drawing
        • Selecting Functional Requirements
        • Shape Development
        • Material Selection
        • Practice for Identifying Process Steps
      • Practice for Developing a Process Step
        • Practice for Developing a Consolidation Step
          • Debulking
          • Consolidation of Thermoplastics
          • Vacuum Bagging
            • Vacuum Bagging for Prepregs
            • Vacuum Bagging for Vacuum Infusion
        • Practice for Developing a Receiving and Storage Step
        • Practice for Developing a Deposition Step
          • Resin degassing
          • Practice for Developing a Wet Lay-up
        • Practice for Developing a Demoulding Step
        • Practice for developing a thermal transformation process step
          • Developing production scale tooling
      • Ensuring quality during production of variable thickness parts
      • Maintaining equivalency during cure for different fibre architectures
      • Ensuring tooling choice meets part quality metrics
      • Ensuring quality during curing of thick parts
    • Production Optimization
      • Process selection for production scale-up
      • Decreasing Cure Cycle Time
      • Practice of Mould Maintenance
      • Increasing throughput by curing parts simultaneously
      • Maintaining quality when scaling-up from coupons to production-ready parts
      • Optimizing a cure cycle for improved production rates
    • Production Troubleshooting
      • Practice for troubleshooting a Light RTM step
      • Maintaining part quality when changing curing equipment
      • Troubleshooting part quality during cure when changing the reinforcement
      • Troubleshooting scale-up issues from thin to thick parts
      • Ensuring appropriate resin flow and part consolidation for a new cure cycle
      • Troubleshooting scaling-up issues from coupons to parts
      • Ensuring appropriate resin flow and part consolidation for a new material
      • Troubleshooting quality issues during cure for different equipment types
      • Troubleshooting scaling issues from small to large parts
      • Transitioning tooling styles between different thermal transformation equipment
      • Troubleshooting when changing production tooling material
      • Troubleshooting tooling to achieve part quality
      • Troubleshooting a cure cycle for improved production rates
  • Case Studies
    • Development
      • Lack of Requirements in Product Development
      • Conducting a thermal tooling survey on three complex tools of different materials
      • Developing for Future Production Scale Up
      • Use of Right Sized Simulation to Aid Decision Making in Thermoplastic Composite Manufacturing Systems
      • Feasibility of Using Composite Materials in Mobile Food Truck Tandoor Ovens
      • Automotive Battery Enclosure Material and Manufacturing Assessment
      • Product Development Stage Gate Methodology for a Composite Shroud
      • Process Selection for a Composite Transit Vehicle Door
    • Optimization
      • Optimization of a hot press process for bike components
      • Optimizing Cost vs Weight for Low Production Volume Parts
      • Cost Comparison Study of a GFRP Leisure Boat Hull Manufacturing Method; Spray Up vs Resin Infusion
      • Using Barcol Hardness Measurements to Correlate Hardness and Degree of Cure
    • Troubleshooting
      • Troubleshooting of room temperature processes for large recreational and industrial parts
  • Perspectives
    • Presentations
      • Dr. Anoush Poursartip's cdmHUB global composites expert webinar
    • Interviews
      • Interview with Prof. Kevin Potter
    • AIM Events - Webinars
      • Cure and thermal management considerations of thermoset composites
      • Introduction to quality assurance and quality control in composites
      • The Current State of Composite Materials in the Bicycle Industry
      • Advanced x-ray imaging of carbon fiber microstructure
      • Implementation of Bolted Joints in Composites
      • Filament Winding
      • Introduction to Bolted Joints in Composites
      • Introduction to Damage and Repair of Composite Sandwich Structures
      • Introduction to Non-Destructive Testing of Composite Materials
      • Introduction to Repair of Composite Structures
      • Viscoelasticity and Composite Materials
      • Introduction to Adhesive Bonding - Part II
      • Introduction to Adhesive Bonding - Part I
      • Sandwich Panels in Aerospace
      • Introduction to Tooling for Composite Materials Processing
      • An Introduction to Composites Sustainability
      • Porosity in Composite Materials - Part II
      • Porosity in Composite Materials - Part I
      • Pultrusion of Thermoplastic Composites
      • Simulation models for rapid liquid composite molding
      • CKN’s Approach to Developing Products with Composite Materials
      • Introduction to Sandwich Structures - Materials and Processing
      • Case Study: Optimizing a Press Moulding Process
      • Introduction to the welding of thermoplastic composites
      • Introduction to the processing of thermoplastic composites
      • Heat Transfer in Composites Processing
      • Effect of cure on mechanical properties of a composite (Part 2 of 2)
      • Effect of cure on mechanical properties of a composite (Part 1 of 2)
      • Fabric Forming: how it affects design and processing, and how simulation can address this
      • Fibre Architecture: Availability, pros and cons, and selection for my application
      • Strengthening the Canadian Advanced Manufacturing Innovation Ecosystem: What types of intellectual property matter, and to whom?
      • Understanding Polyester Resin Processing: The Effect of Ambient Temperature on the Final Part
      • Composites Process Simulation: A Review of the State of the Art for Product Development
      • Resin Behaviour During Processing: What are the key resin properties to consider when developing a manufacturing process?
      • The Composites Knowledge in Practice Centre – an open resource for composites manufacturing knowledge and best practices
      • Deconstructing composites ''processing'' - Why it seems so complex and how to think about it in a structured way
      • Parameters for Structural Analysis of Composites
      • Costing composite parts
      • Composite materials engineering webinar series
        • Composite materials engineering webinar session 1 - Introduction
        • Composite materials engineering webinar session 2 - Constituent Materials - Fiber
        • Composite materials engineering webinar session 3 - Constituent materials - Resin
        • Composite materials engineering webinar session 4 - Thermal management and resin cure
        • Composite materials engineering webinar session 5 - Manufacturing processes - Introduction
        • Composite materials engineering webinar session 6 - Manufacturing processes - Prepreg processing
        • Composite materials engineering webinar session 7 - Manufacturing processes - Liquid composite moulding
        • Composite materials engineering webinar session 8 - Mechanics of composites - Part 1: Lamina level
        • Composite materials engineering webinar session 9 - Mechanics of composites - Part 2: Laminate level
        • Composite materials engineering webinar session 10 - Failure of composites
        • Composite materials engineering webinar session 11 - Defects
        • Composite materials engineering webinar session 12 - Testing
    • Diversity & Inclusion Coffee Breaks
      • D&I featuring Katherine Deane
      • D&I with James Richards
      • D&I with Janice Barton
      • D&I featuring Kero Saleib
      • D&I featuring Rosemary Pham
      • D&I featuring Sampada Bodkhe
      • D&I featuring Isabelle Paris
      • D&I featuring Janic Lauzon
      • D&I featuring Anoush Poursartip
      • D&I featuring Courtney Mandock
  • Resin flow
    • Darcy's law
  • Laminate Plate Theory Calculator
Systems Knowledge - A4Materials deposition and consolidation management (MDCM) - A157

Difference between revisions of "A157"

Draft
Edit with form Edit (VisualEditor)Edit (Source)
Create Outline
Create review View page revision summary
From CKN Knowledge in Practice Centre
(Pushed from CKN Knowledge in Practice Centre.)
 
(Pushed from CKN Knowledge in Practice Centre.)
 
Line 1: Line 1:
 
{{Document
 
{{Document
 
|Increment=157
 
|Increment=157
−
|Page order=9
+
|Page order=13
−
|Document title=Material deposition management
+
|Document title=Materials deposition and consolidation management (MDCM)
 
|Document type=A
 
|Document type=A
 
|Document template=General article
 
|Document template=General article
Line 11: Line 11:
 
|Hide for anonymous=Yes
 
|Hide for anonymous=Yes
 
|Parent document=A4
 
|Parent document=A4
−
|Themes=Material deposition management
+
|Themes=Materials deposition and consolidation management
 
|Tags=System theme
 
|Tags=System theme
 
|RelatedPageTags=System theme
 
|RelatedPageTags=System theme
Line 17: Line 17:
 
}}
 
}}
 
<div class="noexcerpt">
 
<div class="noexcerpt">
−
== Overview ==
+
==Introduction==
 
</div>
 
</div>
−
Material deposition management is concerned with knowing, understanding, and managing how the constituent materials of a composite part are placed onto the tooling, and onto each other. Completing the material deposition process steps and acheiving good quality outcomes in terms of fibre alignment (misorientation, wrinkling and waviness), voids and other factors are very important to the final quality of the part. These process steps can be extremely challenging and time consuming depending on the type of material deposition process steps carried out, the form of the material, and the curvature of the tooling. The combined effect of the material deposition process steps and the subsequent [[A158|flow & consolidation]] and [[A162|thermal transformation]] steps will determine local porosity, resin volume fraction leading to either resin rich or resin starved areas, and fiber misalignment.
 
  
−
Material deposition processes can be broadly separated into “infusion” processes where the fiber is positioned on the tool and then matrix is added, and “wet” or "prepreg" type processes where the fiber and matrix are combined before the mix is positioned on the tool. [[File:FactoryCellLayout-KERL7pPmm5Sm.svg|left|300px|thumb|A factory process flow. The process chosen should not be driven by historical process names often based on material depsoition process steps. Instead, it should be driven by the shape of the part and the material used for the part; these will define the equipment and tooling & consumables that are appropriate, thereby fully defining the [[A230|MSTEP]] collection for each process step.]] Additionally, by convention, the composites industry names and classifies manufacturing processes after one or more critical process steps in the manufacturing workflow (typically a material deposition step) or after the material form that is processed. Some examples of composites manufacturing processes historically named after material deposition process steps are:
 
−
*Vacuum assisted resin infusion (VARI)/vacuum assisted resin transfer moulding (VARTM)
 
−
*Resin transfer moulding (RTM)
 
−
*Spray-up
 
−
*Filament winding
 
−
*Tube rolling
 
−
*Automated fibre placement (AFP)/automated tape laying (ATL)
 
−
While these are common and sometimes useful names for discussing these manufacturing processes with others, it is important to remember that it is actually the part and material that determine which process steps must be performed and which equipment/tooling can be used to perform them. The layout of these process steps are what define the manufacturing workflow rather than a pre-defined manufacturing process. Recognizing this important fact and using it to guide the development of a manufacturing process will ensure that the most appropriate material deposition steps are utilized.
 
  
−
The content related to materials deposition manangement in the Knowledge in Practice Centre is currently quite limited as we are in the early stages of content creation and have focused on the theme of [[A107|thermal management]]. We will be working on material deposition management next, and encourage you to check back in the future for more content in this theme.
+
Material deposition and consolidation management (MDCM) is concerned with knowing, understanding, and managing how the constituent materials of a composite part are placed and consolidated onto the tooling. Whereas the thermal management is relatively independent of process, material deposition and consolidation management is highly dependent on the process, which is likely why most processes are colloquially named after their MDCM step. Material deposition processes can be broadly separated into two categories:
 +
 
 +
* Deposition of the reinforcement onto the tool followed by the deposition of matrix (Tool + Reinforcement + Matrix)
 +
* Reinforcement and Matrix combined, then deposited onto the tool  ((Reinforcement + Matrix) + Tool)
 +
 
 +
 
 +
Regardless of the manufacturing process, material deposition and consolidation have direct impact on cost and final part quality. Depending on the process, material form and part shape, deposition and consolidation can consume a huge amount of time and resources in a manufacturing system, especially for complex and high performance applications. The combined effect of the material deposition and consolidation and the subsequent thermal transformation steps will determine local porosity, resin volume fraction leading to either resin rich or resin starved areas, and fibre misalignment.
 +
 
 +
 
 +
==Significance==
 +
{{Explicit_internal_link|Page=A180|Display= the outcome matrix|Capitalize=Yes}}
 +
Material deposition and consolidation is a major cost driver in composite manufacturing. The capital and overhead cost of MDCM accounts for 40 - 60 % of the total cost depending on part complexity and production volume{{Ref|808e27d6-06b0-3af8-91e7-25bbabb756be}}. Several manufacturing outcomes are directly related to MDCM. This includes wrinkling, fibre waviness, [[A260|Fibre volume fraction]], porosity (void content), residual stress and [[A285|others]]. Further, material deposition rate can directly impact throughput. Choosing the correct manufacturing process and appropriate processing parameters is essential to a composite manufacturing system.
 +
 
 +
==Scope==
 +
This page describes MDCM from a systems level perspective. Since material deposition and consolidation is heavily process dependent, the section is expanded into a comprehensive list of composite manufacturing processes. Two representative processes, vacuum assisted resin transfer moulding (VARTM) from liquid composite moulding and hand layup pre-preg/autoclave are discussed in detail. These two examples demonstrate using the MSTE approach to categorize processing parameter which can affect the MDCM outcomes. Following this approach, the effects of each MSTE parameter class on the MDCM outcomes are analyzed and illustrated in the following subpages:
 +
 
 +
<br clear="all" />
 +
<div class="container-fluid" style="margin-right:auto; margin-left:auto; width:100%;> <!-- Start of table -->
 +
 
 +
<!--Row for Pictures-->
 +
<div class="row">
 +
<div class="col">
 +
<div class="panel res-img100Percent">[[Image:Effect-of-Material-MDM_icon-JJBnrDwmVS9r.svg|center|frameless|link=A267]]
 +
</div>
 +
</div>
 +
<div class="col">
 +
<div class="panel res-img100Percent">[[Image:Effect-of-Shape-MDM_icon-JJBnrDwmVS9r.svg|center|frameless|link=A268]]
 +
</div>
 +
</div>
 +
<div class="col">
 +
<div class="panel res-img100Percent">[[Image:Effect-of-Tooling-MDM_icon-JJBnrDwmVS9r.svg|center|frameless|link=A269]]
 +
</div>
 +
</div>
 +
<div class="col">
 +
<div class="panel res-img100Percent">[[Image:Effect-of-Equipment-MDM_icon-JJBnrDwmVS9r.svg|center|frameless|link=A270]]
 +
</div>
 +
</div>
 +
</div>
 +
 
 +
<!--Row for Captions-->
 +
<div class="row">
 +
<div class="col">
 +
<div class="panel" style="text-align:center">'''Effect of material in a materials deposition and consolidation management system'''
 +
</div>
 +
</div>
 +
<div class="col">
 +
<div class="panel" style="text-align:center">'''Effect of shape in a materials deposition and consolidation management system'''
 +
</div>
 +
</div>
 +
<div class="col">
 +
<div class="panel" style="text-align:center">'''Effect of tooling in a materials deposition and consolidation management system'''
 +
</div>
 +
</div>
 +
<div class="col">
 +
<div class="panel" style="text-align:center">'''Effect of equipment in a materials deposition and consolidation management system'''
 +
</div>
 +
</div>
 +
</div>
 +
 
 +
</div> <!-- end of table -->
 +
 
 +
 
 +
==Systems level approach==
 +
 
 +
===Overview===
 +
Material deposition and consolidation management is highly dependent on the material deposition process. Material deposition processes can be broadly separated into two categories:
 +
 
 +
* Deposition of the reinforcement onto the tool followed by the deposition of matrix (Tool + Reinforcement + Matrix). Some typical processes in this category include:
 +
**[[A290|Vacuum assisted resin transfer moulding (VARTM)/resin infusion (VARI)]]
 +
**[[A184|Light resin transfer moulding (Light RTM)]]
 +
**[[A293|Resin transfer moulding (RTM)]]
 +
**[[A294|Forming (dry charge)]]
 +
**[[A295|Resin injection moulding (RIM)]]
 +
 
 +
* Reinforcement and matrix combined, then deposited onto the tool  ((Reinforcement + Matrix) + Tool). Some typical processes in this category include:
 +
**[[A296|Wet layup]]
 +
** [[A297|Spray-up]]
 +
** [[A298|Pultrusion]]
 +
** [[A299|Filament winding (wet winding)]]
 +
** [[A300|Filament winding (Towpreg winding)]]
 +
** [[A301|Forming (Pre-preg)]]
 +
** [[A302|Compression moulding (SMC/BMC)]]
 +
** [[A291|Hand layup prepreg (Autoclave/Out-of-autoclave) processing - A291]]
 +
** [[A303|Automated fibre placement (AFP)]]
 +
** [[A304|Automated tape layup (ATL)]]
 +
** [[A305|Bladder moulding]]
 +
** [[A306|Tube Rolling]]
 +
** [[A307|Centrifugal casting]]
 +
** [[A308|Continuous Lamination]]
 +
'''
 +
[Explain the physics in relation to the outcomes in two phases: first one only for first category, second true for both] and link to the example below (replace ex. 2 with autoclave process).'''
 +
 
 +
 
 +
===Example 1: Vacuum assisted resin transfer moulding (VARTM)/resin infusion (VARI)===
 +
<imagemap>
 +
Image:VA-RTM_and_Light_RTM_Factory_Workflow-8Xgd4kPBNzPm.svg|1000 px
 +
rect 135 5 155 25 [[P105|Practice for developing a thermal transformation process step]]
 +
rect 262 5 282 25 [[P105|Practice for developing a thermal transformation process step]]
 +
rect 326 5 346 25 [[P105|Practice for developing a thermal transformation process step]]
 +
desc none
 +
</imagemap>
 +
 
 +
 
 +
MSTE under the context of MDCM for [[A290|Vacuum assisted resin transfer moulding (VARTM)/resin infusion (VARI)]] are:
 +
====Material====
 +
* Material Structure
 +
**[[A200|+Reinforcement sizing]] - sizing serves the interface between the reinforcement and the matrix. Sizing can affect how the reinforcement is impregnated *NOTE: in this case, the term sizing has nothing to do with the physical size of the fibre
 +
**[[A201|+Reinforcement architecture]] - tow size can affect the impregnation. Large tow size, potential porosity within the tow. Small tow size, potential porosity between the tows (Ask Casey for figure/schematic)
 +
*Material properties
 +
**[[A262|Fibre-bed drapability]] - how well fibre will conform to the shape of the tool. Plays a role in fibre waviness
 +
**[[A259|Fibre-bed permeability]] - Along with Viscosity (resin) and pressure differential, determines the rate at which resin infused the fibre
 +
**[[A203|Viscosity (resin)]] - Along with Fibre-bed permeability and pressure differential, determines the resin deposition rate
 +
*Consumables
 +
Vacuum bags, spiral tubing, peel ply, flow media and other consumables play crucial roles in VARTM. Consolidation of VARTM is solely provided by vacuum pressure via the vacuum bag. Spiral tubing and flow media assist the resin deposition (flow) to fully impregnate the reinforcement. 
 +
====Shape====
 +
*Geometry - VARTM can adopt a wide range of size and shape complexities. In theory, a shape is achievable if the reinforcement can be deposited and resin flow can reach. In practice, sharp/tight turns and undercuts are difficult to fully infuse. Reinforcement is typically deposited manually if the shape is simple. A small amount of adhesive (often 'spray glue') is sometimes used to stop the consumables and reinforcements from shifting. For complex shapes, reinforcement preforms can be used.
 +
**Thickness - affects the through thickness resin flow front profile
 +
**Corners and curvature - tight convex corners raises pressure, leading to thinner part. Tight concave corner can potentially cause resin pooling and resin rich areas
 +
 
 +
====Tool====
 +
*Tool determines the shape
 +
====Equipment====
 +
*Fibre cutting equipment - potentially cause fibre waviness
 +
*Fibre handling equipment - potentially cause fibre waviness and misalignment
 +
*Vacuum pump - determines the vacuum level and consolidation force exerted on the part
 +
 
 +
 
 +
===Example 2: Hand layup prepreg (Autoclave/Out-of-autoclave) processing===
 +
 
 +
<imagemap>
 +
Image:Autoclave_OoA_Factory_Workflow-8Xgd4kPBNzPm.svg|x85px
 +
rect 179 7 206 33 [[P105|Practice for developing a thermal transformation process step]]
 +
rect 264 7 291 33 [[P105|Practice for developing a thermal transformation process step]]
 +
desc none
 +
</imagemap>
 +
 
 +
Depositing pre-preg material using hand layup is intrinsically slower and more prone to errors and uncertainties comparing to [[A303|Automated fibre placement (AFP)]] or [[A304|Automated tape layup (ATL)]]. However, for small and intricate parts, hand layup can be a lot more robust for manipulating the pre-preg sheet onto complex contours. MSTE under the context of MDCM for [[A291|Hand layup prepreg (Autoclave/Out-of-autoclave) processing - A291]] are:
 +
====Material====
 +
* Material Structure
 +
**[[A258|Reinforcement architecture]] - Unidirectional or woven; tow size and deposition rate
 +
**[[A202|Inserts]] - The use of inserts complicates the MDCM, depending on the insert type, sealant or other insert associated consumables are potential required. Potential cure in multiple stages.
 +
*Material properties
 +
**[[A262|Fibre-bed drapability]] - how well fibre will conform to the shape of the tool. Plays a role in fibre waviness
 +
**[[A203|Viscosity (resin)]] - Along with Fibre-bed permeability, determines the resin deposition rate. Function of temperature, warming up the pre-preg softens the resin, making hand layup easier. {{#evu:https://vimeo.com/639703238#t=23m15s}}
 +
*Consumables
 +
Vacuum bags, breather cloth and release films are used during de-bulking and curing. The layup is typically debulked every three to five layers depending on the shape complexity. Debulking compacts the layup and removes entrapped air between the pre-preg layers. Debulking can also be perform at elevated temperatures (65.5°C to 93.3 °C or 150 °F to 200 °F) to soften the resin for better consolidation{{Ref|808e27d6-06b0-3af8-91e7-25bbabb756be}}.
 +
 
 +
====Shape====
 +
*Thickness - The thicker the part, the more layers of pre-preg required, longer it takes to complete layup
 +
*Layup - more complex the layup, lower the deposition rate, higher uncertainties and chance for error
 +
*Corners and curvature - tight convex corners raises pressure, leading to thinner part. Tight concave corner can potentially cause resin pooling and resin rich areas
 +
*Gapping - when gapping is required, hand layup can be inaccurate which may cause resin rich areas or other defects
 +
====Tool====
 +
*Tool determines the shape
 +
====Equipment====
 +
*Fibre cutting equipment - potentially cause fibre waviness
 +
*Fibre handling equipment - potentially cause fibre waviness and misalignment
 +
*Vacuum pump - determines the vacuum level and consolidation force exerted on the part
 +
*[[A173|Autoclave]] - As temperature increases initially [[A203|Viscosity (resin)]] decrease, along with the autoclave pressure, part is consolidated
 +
 
 +
 
 +
===Manufacturing outcomes/MDCM outcomes===
 +
 
 +
*Fibre waviness
 +
*Fibre misalignment
 +
*Wrinkles
 +
*Variation in [[A260|Fibre volume fraction]]
 +
*Porosity (void content)
 +
 
 +
<headertabs />
 +
 
 
{{Get Subpages}}
 
{{Get Subpages}}
 +
 
{{Get Related pages}}
 
{{Get Related pages}}
 +
 
{{Get Footnotes and References}}
 
{{Get Footnotes and References}}
 +
 
{{Get contributors}}
 
{{Get contributors}}
 +
 
{{Footer}}
 
{{Footer}}

Latest revision as of 02:07, 26 February 2022

 
Materials deposition and consolidation management (MDCM)
Systems knowledge article
MDM Icon-JJBnrDwmVS9r.svg
Document Type Article
Document Identifier 157
Themes
Tags
Prerequisites

Introduction[edit | edit source]


Material deposition and consolidation management (MDCM) is concerned with knowing, understanding, and managing how the constituent materials of a composite part are placed and consolidated onto the tooling. Whereas the thermal management is relatively independent of process, material deposition and consolidation management is highly dependent on the process, which is likely why most processes are colloquially named after their MDCM step. Material deposition processes can be broadly separated into two categories:

  • Deposition of the reinforcement onto the tool followed by the deposition of matrix (Tool + Reinforcement + Matrix)
  • Reinforcement and Matrix combined, then deposited onto the tool ((Reinforcement + Matrix) + Tool)


Regardless of the manufacturing process, material deposition and consolidation have direct impact on cost and final part quality. Depending on the process, material form and part shape, deposition and consolidation can consume a huge amount of time and resources in a manufacturing system, especially for complex and high performance applications. The combined effect of the material deposition and consolidation and the subsequent thermal transformation steps will determine local porosity, resin volume fraction leading to either resin rich or resin starved areas, and fibre misalignment.


Significance[edit | edit source]

Link to the outcome matrix

Material deposition and consolidation is a major cost driver in composite manufacturing. The capital and overhead cost of MDCM accounts for 40 - 60 % of the total cost depending on part complexity and production volume[1]. Several manufacturing outcomes are directly related to MDCM. This includes wrinkling, fibre waviness, Fibre volume fraction, porosity (void content), residual stress and others. Further, material deposition rate can directly impact throughput. Choosing the correct manufacturing process and appropriate processing parameters is essential to a composite manufacturing system.

Scope[edit | edit source]

This page describes MDCM from a systems level perspective. Since material deposition and consolidation is heavily process dependent, the section is expanded into a comprehensive list of composite manufacturing processes. Two representative processes, vacuum assisted resin transfer moulding (VARTM) from liquid composite moulding and hand layup pre-preg/autoclave are discussed in detail. These two examples demonstrate using the MSTE approach to categorize processing parameter which can affect the MDCM outcomes. Following this approach, the effects of each MSTE parameter class on the MDCM outcomes are analyzed and illustrated in the following subpages:


Effect-of-Material-MDM icon-JJBnrDwmVS9r.svg
Effect-of-Shape-MDM icon-JJBnrDwmVS9r.svg
Effect-of-Tooling-MDM icon-JJBnrDwmVS9r.svg
Effect-of-Equipment-MDM icon-JJBnrDwmVS9r.svg
Effect of material in a materials deposition and consolidation management system
Effect of shape in a materials deposition and consolidation management system
Effect of tooling in a materials deposition and consolidation management system
Effect of equipment in a materials deposition and consolidation management system


Systems level approach[edit | edit source]

Overview[edit | edit source]

Material deposition and consolidation management is highly dependent on the material deposition process. Material deposition processes can be broadly separated into two categories:

[Explain the physics in relation to the outcomes in two phases: first one only for first category, second true for both] and link to the example below (replace ex. 2 with autoclave process).


Example 1: Vacuum assisted resin transfer moulding (VARTM)/resin infusion (VARI)[edit | edit source]

Practice for developing a thermal transformation process stepPractice for developing a thermal transformation process stepPractice for developing a thermal transformation process stepVA-RTM and Light RTM Factory Workflow-8Xgd4kPBNzPm.svg


MSTE under the context of MDCM for Vacuum assisted resin transfer moulding (VARTM)/resin infusion (VARI) are:

Material[edit | edit source]

  • Material Structure
    • +Reinforcement sizing - sizing serves the interface between the reinforcement and the matrix. Sizing can affect how the reinforcement is impregnated *NOTE: in this case, the term sizing has nothing to do with the physical size of the fibre
    • +Reinforcement architecture - tow size can affect the impregnation. Large tow size, potential porosity within the tow. Small tow size, potential porosity between the tows (Ask Casey for figure/schematic)
  • Material properties
    • Fibre-bed drapability - how well fibre will conform to the shape of the tool. Plays a role in fibre waviness
    • Fibre-bed permeability - Along with Viscosity (resin) and pressure differential, determines the rate at which resin infused the fibre
    • Viscosity (resin) - Along with Fibre-bed permeability and pressure differential, determines the resin deposition rate
  • Consumables

Vacuum bags, spiral tubing, peel ply, flow media and other consumables play crucial roles in VARTM. Consolidation of VARTM is solely provided by vacuum pressure via the vacuum bag. Spiral tubing and flow media assist the resin deposition (flow) to fully impregnate the reinforcement.

Shape[edit | edit source]

  • Geometry - VARTM can adopt a wide range of size and shape complexities. In theory, a shape is achievable if the reinforcement can be deposited and resin flow can reach. In practice, sharp/tight turns and undercuts are difficult to fully infuse. Reinforcement is typically deposited manually if the shape is simple. A small amount of adhesive (often 'spray glue') is sometimes used to stop the consumables and reinforcements from shifting. For complex shapes, reinforcement preforms can be used.
    • Thickness - affects the through thickness resin flow front profile
    • Corners and curvature - tight convex corners raises pressure, leading to thinner part. Tight concave corner can potentially cause resin pooling and resin rich areas

Tool[edit | edit source]

  • Tool determines the shape

Equipment[edit | edit source]

  • Fibre cutting equipment - potentially cause fibre waviness
  • Fibre handling equipment - potentially cause fibre waviness and misalignment
  • Vacuum pump - determines the vacuum level and consolidation force exerted on the part


Example 2: Hand layup prepreg (Autoclave/Out-of-autoclave) processing[edit | edit source]

Practice for developing a thermal transformation process stepPractice for developing a thermal transformation process stepAutoclave OoA Factory Workflow-8Xgd4kPBNzPm.svg

Depositing pre-preg material using hand layup is intrinsically slower and more prone to errors and uncertainties comparing to Automated fibre placement (AFP) or Automated tape layup (ATL). However, for small and intricate parts, hand layup can be a lot more robust for manipulating the pre-preg sheet onto complex contours. MSTE under the context of MDCM for Hand layup prepreg (Autoclave/Out-of-autoclave) processing - A291 are:

Material[edit | edit source]

  • Material Structure
    • Reinforcement architecture - Unidirectional or woven; tow size and deposition rate
    • Inserts - The use of inserts complicates the MDCM, depending on the insert type, sealant or other insert associated consumables are potential required. Potential cure in multiple stages.
  • Material properties
    • Fibre-bed drapability - how well fibre will conform to the shape of the tool. Plays a role in fibre waviness
    • Viscosity (resin) - Along with Fibre-bed permeability, determines the resin deposition rate. Function of temperature, warming up the pre-preg softens the resin, making hand layup easier.
  • Consumables

Vacuum bags, breather cloth and release films are used during de-bulking and curing. The layup is typically debulked every three to five layers depending on the shape complexity. Debulking compacts the layup and removes entrapped air between the pre-preg layers. Debulking can also be perform at elevated temperatures (65.5°C to 93.3 °C or 150 °F to 200 °F) to soften the resin for better consolidation[1].

Shape[edit | edit source]

  • Thickness - The thicker the part, the more layers of pre-preg required, longer it takes to complete layup
  • Layup - more complex the layup, lower the deposition rate, higher uncertainties and chance for error
  • Corners and curvature - tight convex corners raises pressure, leading to thinner part. Tight concave corner can potentially cause resin pooling and resin rich areas
  • Gapping - when gapping is required, hand layup can be inaccurate which may cause resin rich areas or other defects

Tool[edit | edit source]

  • Tool determines the shape

Equipment[edit | edit source]

  • Fibre cutting equipment - potentially cause fibre waviness
  • Fibre handling equipment - potentially cause fibre waviness and misalignment
  • Vacuum pump - determines the vacuum level and consolidation force exerted on the part
  • Autoclave - As temperature increases initially Viscosity (resin) decrease, along with the autoclave pressure, part is consolidated


Manufacturing outcomes/MDCM outcomes[edit | edit source]


Related pages

Page type Links
Introduction to Composites Articles
Foundational Knowledge Articles
Foundational Knowledge Method Documents
Foundational Knowledge Worked Examples
Systems Knowledge Articles
Systems Knowledge Method Documents
Systems Knowledge Worked Examples
Systems Catalogue Articles
Systems Catalogue Objects – Material
Systems Catalogue Objects – Shape
Systems Catalogue Objects – Tooling and consumables
Systems Catalogue Objects – Equipment
Practice Documents
Case Studies
Perspectives Articles

References

  1. ↑ Jump up to: 1.0 1.1 [Ref] Campbell, F.C. (2004). Manufacturing Processes for Advanced Composites. Elsevier. doi:10.1016/B978-1-85617-415-2.X5000-X. ISBN 9781856174152.CS1 maint: uses authors parameter (link) CS1 maint: date and year (link)



About-hpWrZW97CxCB.svg
Help-hlkrZW15CxCB.svg
About Help

The individual materials that combine to form the composite material. The constituent materials are separate and distinct on a macroscopic level.

Engineered materials (designed to have specific properties) made from two or more constituent materials with different physical or chemical properties. The constituents remain separate and distinct on a macroscopic level within the finished structure.

A central processing theme in the manufacturing cycle. This theme is concerned with managing the thermal response of materials during storage and handling or parts/tools when they are subsequently heated.

The continuous material phase that binds the reinforcement together, maintains shape, transfers load, protects the reinforcement from environment and damage, and provides the composite support in compression.

Desirable characteristics:

  • Moisture/chemical resistance
  • Low density
  • Processability

For polymer matrix composites (PMCs), resin refers to the matrix; the continuous material phase that binds the reinforcement together, maintains shape, and transfers load. Resins are divided into two main groups: thermosets and thermoplastics.

Volume fraction of either matrix or fibres with respect to total composite volume (matrix + fibre).

Outcomes represent the range of response/sensitivity to factory system attributes. Those that fail to satisfy manufacturing requirements are known as defects. Examples of manufacturing outcomes include process parameter outcomes, material structure outcomes, and material performance outcomes.

Vacuum assisted resin transfer moulding (VARTM) - also known as vacuum assisted resin infusion (VARI), vacuum infusion process (VIP) or often just resin infusion. VARTM is a liquid composite moulding (LCM) closed mould process with a single side tool and vacuum bag where the resin is drawn through the preform using vacuum.

Vacuum assisted resin infusion (VARI) - also known as vacuum assisted resin transfer moulding (VARTM), vacuum infusion process (VIP) or often just resin infusion. VARI is a liquid composite moulding (LCM) closed mould process with a single side tool and vacuum bag where the resin is drawn through the preform using vacuum.

Sizing or fibre sizing refers to a coating that is applied to fibre during manufacturing. Highly proprietary (formulation and process).

Sizing serves two functions:

  • Protects and aids fibre during processing
  • Aids in the bonding of fibre and matrix

A tow is a bundle or yarn of individual fibres. The tow size is inherent to the fibre manufacturing process (i.e. a tow is manufactured in one process, rather than each fibre individually then bundled together after).

Typically, smaller tows are better because they result in a more homogeneous material.

The larger the tow:

  • The faster it is to deposit material
  • The easier is it for resin to flow between tows
  • Harder for resin to saturate


Typical tow sizes:

  • 1k (thousand)
  • 3k
  • 6k
  • 12k
  • 24k
  • 50k

Permeability refers to the resistance to fluid flow through a porous material.

  • Resin flow through fibre
  • Gas flow through prepreg

Any manufacturing and/or decision making activity that occurs during any stage of the development design cycle (e.g. conceptual design to production).

In the context of Knowledge in Practice, practice refers to the systematic use of science based knowledge to reduce composites manufacturing risk, cost, and development time.

Flow front refers to the leading edge of the resin as it is flowing into and through the fibre preform.

Pre-impregnated (prepreg) material refers to fibre that is already combined with resin. It is the most common material form used in aerospace.

During prepreg production, (e.g. fibres are run through a resin bath), prepreg is heated and partially cured to B Stage (< 5 % degree of cure). Thermoset prepregs (e.g. epoxy prepreg) have to be kept in a freezer at around -20 °C. At room temperature, the epoxy starts to cure.

Retrieved from "https://compositeskn.org/KPC/index.php?title=A157&oldid=5979"
CKN KPC logo

Welcome

Welcome to the CKN Knowledge in Practice Centre (KPC). The KPC is a resource for learning and applying scientific knowledge to the practice of composites manufacturing. As you navigate around the KPC, refer back to the information on this right-hand pane as a resource for understanding the intricacies of composites processing and why the KPC is laid out in the way that it is. The following video explains the KPC approach:

Understanding Composites Processing

The Knowledge in Practice Centre (KPC) is centered around a structured method of thinking about composite material manufacturing. From the top down, the heirarchy consists of:

The way that the material, shape, tooling & consumables and equipment (abbreviated as MSTE) interact with each other during a process step is critical to the outcome of the manufacturing step, and ultimately critical to the quality of the finished part. The interactions between MSTE during a process step can be numerous and complex, but the Knowledge in Practice Centre aims to make you aware of these interactions, understand how one parameter affects another, and understand how to analyze the problem using a systems based approach. Using this approach, the factory can then be developed with a complete understanding and control of all interactions.

The relationship between material, shape, tooling & consumables and equipment during a process step


Interrelationship of Function, Shape, Material & Process

Design for manufacturing is critical to ensuring the producibility of a part. Trouble arises when it is considered too late or not at all in the design process. Conversely, process design (controlling the interactions between shape, material, tooling & consumables and equipment to achieve a desired outcome) must always consider the shape and material of the part. Ashby has developed and popularized the approach linking design (function) to the choice of material and shape, which influence the process selected and vice versa, as shown below:

The relationship between function, material, shape and process


Within the Knowledge in Practice Centre the same methodology is applied but the process is more fully defined by also explicitly calling out the equipment and tooling & consumables. Note that in common usage, a process which consists of many steps can be arbitrarily defined by just one step, e.g. "spray-up". Though convenient, this can be misleading.

The relationship between function, material, shape and process consisting of Equipment and Tooling and consumables


Workflows

The KPC's Practice and Case Study volumes consist of three types of workflows:

  • Development - Analyzing the interactions between MSTE in the process steps to make decisions on processing parameters and understanding how the process steps and factory cells fit within the factory.
  • Troubleshooting - Guiding you to possible causes of processing issues affecting either cost, rate or quality and directing you to the most appropriate development workflow to improve the process
  • Optimization - An expansion on the development workflows where a larger number of options are considered to achieve the best mixture of cost, rate & quality for your application.

To use this website, you must agree to our Terms and Conditions and Privacy Policy.

By clicking "I Accept" below, you confirm that you have read, understood, and accepted our Terms and Conditions and Privacy Policy.

Powered by MediaWiki
Powered by Semantic MediaWiki