Processing of Composites

Front Matter......Page p0002.djvu
Foreword......Page p0007.djvu
Contributors......Page p0009.djvu
Preface......Page p0011.djvu
Contents......Page p0022.djvu
Part I Theory......Page p0032.djvu
1.1 Overview......Page p0033.djvu
1.2 Chemistry of Anionic Ring Opening Polymerization of Lactams......Page p0038.djvu
1.3.1 Kinetics Model......Page p0040.djvu
1.3.2 Kinetic Model Verification......Page p0043.djvu
1.4 Viscosity Growth during Anionic Polymerization of Caprolactam......Page p0046.djvu
1.4.2 Viscosity Model Verification......Page p0047.djvu
1.5 Application of Rheo-Kinetics Modeling to Reaction Injection Pultrusion......Page p0052.djvu
Nomenclature......Page p0058.djvu
References......Page p0059.djvu
2. Thermoset Resin Cure Kinetics and Rheology......Page p0062.djvu
2.1.1 Resins......Page p0063.djvu
2.1.2 Reinforcements......Page p0064.djvu
2.1.4 Cure Cycles......Page p0065.djvu
2.1.5 Optimization......Page p0066.djvu
2.2 Cure Kinetics......Page p0067.djvu
2.2.1 Kinetic Models......Page p0068.djvu
2.2.2 Gelation Theory......Page p0071.djvu
2.2.3 Rheological Models......Page p0073.djvu
2.2.5 Techniques to Monitor Cure......Page p0076.djvu
2.3 Effect of Reinforcements......Page p0081.djvu
2.4.1 Epoxies......Page p0082.djvu
2.4.2 Vinyl Esters......Page p0084.djvu
3. Phase Separation and Morphology Development during Curing of Toughened Thermosets......Page p0100.djvu
3.2 Phase Separation in Terms of Thermodynamics and Kinetics......Page p0101.djvu
3.3 Literature Review......Page p0103.djvu
3.4.2 Blending and Curing Procedure......Page p0109.djvu
3.5.1 Phase Diagram......Page p0110.djvu
3.5.3 Phase Separation Mechanism......Page p0111.djvu
3.5.4 Effect of Composition......Page p0123.djvu
3.6 Conclusions......Page p0126.djvu
References......Page p0127.djvu
4.1 Introduction......Page p0129.djvu
4.3 Theory......Page p0132.djvu
4.4 Isothermal Cure......Page p0133.djvu
4.5 Monitoring Cure in Multiple Time Temperature Processing Cycles......Page p0137.djvu
4.6 Monitoring Cure in a Thick Laminate......Page p0140.djvu
4.7 Resin Film Infusion......Page p0143.djvu
4.8 Smart Automated Control......Page p0146.djvu
References......Page p0148.djvu
5.1 Introduction......Page p0150.djvu
5.2 Local Volume Averaging......Page p0151.djvu
5.3.1 Conservation of Mass......Page p0153.djvu
5.3.2 Conservation of Momentum......Page p0155.djvu
5.3.3 Conservation of Energy......Page p0157.djvu
5.4 Specialized Equations for Various Polymer Matrix Composite Manufacturing Processes......Page p0159.djvu
5.4.1 Resin Transfer Molding (RTM)......Page p0160.djvu
5.4.2 Injected Pultrusion (IP)......Page p0162.djvu
5.4.3 Autoclave Processing (AP)......Page p0169.djvu
5.5 Conclusions......Page p0170.djvu
Nomenclature......Page p0171.djvu
References......Page p0172.djvu
6.1 Introduction......Page p0174.djvu
6.1.1 The Autoclave Process......Page p0175.djvu
6.2 Void Formation and Equilibrium Stability......Page p0177.djvu
6.2.1 Nucleation of Voids......Page p0178.djvu
6.2.2 Void Stability at Equilibrium......Page p0179.djvu
6.3.1 Problem Definition......Page p0182.djvu
6.3.2 Model Development......Page p0183.djvu
6.3.3 Model Predictions for Void Growth......Page p0187.djvu
6.4 Resin and Void Transport......Page p0193.djvu
6.5 Conclusions......Page p0196.djvu
Nomenclature......Page p0197.djvu
References......Page p0198.djvu
7. Consolidation during Thermoplastic Composite Processing......Page p0200.djvu
7.1 Introduction......Page p0201.djvu
7.2 Intimate Contact......Page p0204.djvu
7.2.1 Literature Review......Page p0205.djvu
7.2.2 Intimate Contact Model......Page p0207.djvu
7.2.3 Intimate Contact Measurements......Page p0214.djvu
7.2.4 Model Verification......Page p0216.djvu
7.2.5 Parametric Study......Page p0220.djvu
7.3 Interply Bonding......Page p0223.djvu
7.3.1 Healing Model......Page p0225.djvu
7.3.2 Degree of Bonding......Page p0227.djvu
Nomenclature......Page p0228.djvu
References......Page p0229.djvu
8. Processing-Induced Residual Stresses in Composites......Page p0231.djvu
8.1 Introduction......Page p0232.djvu
8.2.1 Cure Kinetics......Page p0234.djvu
8.2.2 Thermochemical Modeling......Page p0237.djvu
8.2.3 Residual Stress Modeling......Page p0242.djvu
8.3 Experimental Results......Page p0250.djvu
8.3.1 Elastic Model Correlation......Page p0251.djvu
8.3.2 Viscoelastic Model Correlation......Page p0252.djvu
8.4.1 Cure Temperature......Page p0255.djvu
8.4.2 Postcure......Page p0256.djvu
8.4.3 Three-Step Cure Cycles......Page p0258.djvu
8.5 Conclusions......Page p0260.djvu
Nomenclature......Page p0261.djvu
References......Page p0262.djvu
9.1 Introduction......Page p0264.djvu
9.2 Traditional Approaches Using SPC/SQC......Page p0265.djvu
9.3 Knowledge-Based (Expert System) Control......Page p0267.djvu
9.4.1 Model-Predictive Control of Continuous Processes......Page p0270.djvu
9.4.2 Model Predictive Control of Batch Processes (SHMPC)......Page p0271.djvu
9.5.1 Categories of Models......Page p0275.djvu
9.5.2 ANNs as On-Line Quality Models for SHMPC......Page p0276.djvu
9.5.3 Applications to Autoclave Curing......Page p0277.djvu
9.6 Summary and Future Trends......Page p0280.djvu
Nomenclature......Page p0281.djvu
References......Page p0283.djvu
Part II Process......Page p0285.djvu
10. Autoclave Processing......Page p0286.djvu
10.1 Introduction......Page p0287.djvu
10.2.1 The Cure Cycle......Page p0288.djvu
10.2.2 Resin Viscosity and Kinetic Models......Page p0289.djvu
10.2.3 Resin Hydrostatic Pressure and Flow......Page p0290.djvu
10.2.4 Resin Flow Models......Page p0291.djvu
10.2.5 Experimental Studies......Page p0292.djvu
10.2.6 Caul Plates and Pressure Intensifiers......Page p0294.djvu
10.2.7 Net Resin and Low Flow Resin Systems......Page p0296.djvu
10.3.1 Theory of Void Formation......Page p0297.djvu
10.3.3 Resin and Prepreg Variables......Page p0298.djvu
10.3.4 Debulking Operations......Page p0299.djvu
10.3.5 Debulking Studies......Page p0300.djvu
10.4.1 Part Thermal Response......Page p0302.djvu
10.4.2 Heat Transfer Models......Page p0304.djvu
10.5 Conclusions......Page p0305.djvu
References......Page p0306.djvu
11. Pultrusion......Page p0308.djvu
11.1 Introduction......Page p0309.djvu
11.2.1 Equipment......Page p0310.djvu
11.2.2 Materials......Page p0314.djvu
11.2.3 Market......Page p0315.djvu
11.2.4 Process Characteristics......Page p0316.djvu
11.2.5 Key Technology Issues......Page p0318.djvu
11.2.6 Pultrusion of Thermoplastic-Matrix Composites......Page p0319.djvu
11.3 Process Modeling......Page p0320.djvu
11.3.1 How Can Modeling Help?......Page p0321.djvu
11.3.2 Previous Modeling Work......Page p0322.djvu
11.4 Matrix Flow Modeling......Page p0323.djvu
12. Principles of Liquid Composite Molding......Page p0327.djvu
12.1 Introduction......Page p0328.djvu
12.2 Preforming......Page p0330.djvu
12.2.1 Cut and Paste......Page p0332.djvu
12.2.3 Thermoforming......Page p0333.djvu
12.3.1 Theoretical Considerations......Page p0334.djvu
12.3.2 Injection Strategies......Page p0337.djvu
12.3.3 Mold-Filling Problems......Page p0341.djvu
12.4.2 Optimization of Cure......Page p0345.djvu
12.4.3 Cure Problems......Page p0347.djvu
12.5.1 General Design Rules......Page p0349.djvu
12.5.2 Mold Materials......Page p0350.djvu
12.5.3 Stiffness Dimensioning......Page p0351.djvu
12.5.4 Sealings......Page p0352.djvu
12.5.6 Heating Systems......Page p0353.djvu
Nomenclature......Page p0354.djvu
References......Page p0355.djvu
13. Filament Winding......Page p0357.djvu
13.1 Introduction......Page p0358.djvu
13.2.1 Winding Techniques......Page p0361.djvu
13.2.2 Fibers and Resins......Page p0362.djvu
13.3 Equipment......Page p0364.djvu
13.4 Cylinder Design Guidelines......Page p0365.djvu
13.5 Filament-Winding Process Models......Page p0367.djvu
13.5.1 Thermochemical Submodel......Page p0369.djvu
13.5.2 Fiber Motion Submodel: Thermosetting Matrix Cylinders......Page p0370.djvu
13.5.3 Consolidation Submodel: Thermoplastic Cylinders......Page p0373.djvu
13.5.4 Stress Submodel......Page p0375.djvu
13.5.5 Void Submodel......Page p0376.djvu
13.6.1 Overview......Page p0377.djvu
13.6.2 Test Methods......Page p0378.djvu
References......Page p0384.djvu
14. Dieless Forming of Thermoplastic-Matrix Composites......Page p0387.djvu
14.1 Introduction......Page p0388.djvu
14.2 Dieless Forming Concept......Page p0389.djvu
14.3 Simulations, Shape Categories, and Forming Machine Concepts......Page p0391.djvu
14.4 Near-Term Demonstration Machine......Page p0395.djvu
14.5 Overcurvarure - Observations and Model......Page p0397.djvu
14.6 Continuous Dieless Forming......Page p0399.djvu
14.7 Forming Arbitrary Curved Shapes Without Dies......Page p0404.djvu
14.8 Summary and Conclusions......Page p0407.djvu
References......Page p0409.djvu
15. Intelligent Processing Tools for Composite Processing......Page p0411.djvu
15.2 The Batch Process Control Problem......Page p0412.djvu
15.3 Tools for Planning Process Conditions......Page p0414.djvu
15.3.1 Trial and Error......Page p0415.djvu
15.3.2 Design of Experiment......Page p0417.djvu
15.4 Statistical Process Control......Page p0419.djvu
15.4.1 Process Science......Page p0420.djvu
15.4.2 Analytical Models......Page p0422.djvu
15.4.3 Knowledge-Based Expert Systems......Page p0425.djvu
15.4.5 Summary of Methods......Page p0426.djvu
15.5 Tools for Real-Time Process Control......Page p0427.djvu
15.5.1 Supervisory Controllers......Page p0428.djvu
15.5.2 Knowledge-Based Adaptive Controllers......Page p0430.djvu
15.5.3 Expert Systems......Page p0431.djvu
15.5.4 Qualitative Reasoning......Page p0432.djvu
15.5.6 Artificial Neural Networks......Page p0434.djvu
15.5.7 Analytical Models......Page p0435.djvu
15.6 Summary......Page p0436.djvu
References......Page p0437.djvu
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