Closed Moulding Process
Closed Moulding Process
Closed Moulding Process
1. Compression Molding:
Fully formed parts are molded in matched metal compression molds that give the final part
shape using pressure and temperature.
After placing the laminate to be cured called the charge in the core of the mold, the cavity
is then closed at the rate of usually 4-12 mm/sec.
The molding pressure based on the projected area ranges from 0.7 to 9 MPa (100 to 1200
psi).
If the resin cure exotherm is not properly controlled, cracking, blistering or warping may
occur.
Vacuum Bagging techniques have been developed for fabricating variety of aerospace
composites and structures.
The required number of piles are cut to size and positioned in a mold.
When individual piles of a prepreg material are formed to the lay-up tool, certain amount
of voids exits between layers.
The lay-up is covered with a flexible membrane or vacuum bag, which is sealed around
the edges of the mold by a sealant.
Good and high capacity vacuum path to be provided to evacuate air from between the bag
and the tool.
(i)
i.
ii.
The composite piles are applied and rubbed to remove the entrapped air.
A perforated film is applied over the composite laminate and extended approximately 3.2
mm beyond all edges.
A predetermined number of bleeder plies are applied over the release film and extended to
the perimeter of the lay-up.
A perforated release film is applied over the lay-up and extended over the release film.
The contents are evacuated and the bag is checked and sealed against leaks.
This allows for a better control of the resin content of the composite structures.
Vacuum Bag Bridging causes resin rich and excessive voids in the corners of composite
laminates.
(ii)
To reduce the material and recurring cost of the expendable vacuum bags, Silicone rubber
reusable bags are used.
The Vacuum bag reduces the amount of volatiles emitted during cure.
The extra process adds cost both in labor and in disposable bagging materials.
Mixing and control of resin content largely still determined by operator skill.
3. Injection Molding:
It refers to the process that generally involves forcing or injecting a fluid plastic
material into a closed mold.
The molding compound is fed into injection chamber through the feed hopper.
Not all the plastics are molded except thermoplastic and thermosets.
It is closed mold low pressure process that allows the fabrication of composites.
The dry reinforcement and the resin are combined within the mold to form the composite
component.
The fiber reinforcement is placed into the cavity tool and closed.
The liquid resin is pumped into the cavity tool to impregnate the reinforcement.
The displaced air is allowed to escape through the vents to avoid dry spots.
Advantages of RTM:
Disadvantages of RTM:
Uncontrolled flow pattern of resin and so resin rich edges are possible.
VARTM employs the injection of resin along with vacuum and captured under a bag
thoroughly impregnate the fiber reinforcements.
Fabric are laid up as dry stack and covered with peel ply and a knitted type non-structural
fabric.
The whole dry stack is vacuum bagged and leaks if any are eliminated and the resin is
allowed to flow through the laminates.
The resin distribution is aided by flowing resin easily through the non-structural fabric and
wetting the fabric.
Advantages of VARTM:
Much lower cost due to the usage of one half of the tool being the vacuum bag.
Disadvantages of VARTM:
Dry fabrics are laid up interleaved with layers of semi-solid resin film supplied on a release
paper.
The lay-up is vacuum bagged to remove air through the dry fabrics.
It is then heated to allow the resin melt and flow into the air-free fabrics and a certain time
to cure.
Advantages of RFI:
High resin mechanical properties due to solid state of initial polymer materials and elevated
temperature cure.
Disadvantages of RFI: