Processing of composites / R.S. Davé, A.C. Loos (editors) ; with contributions from F. Abrams ... [and others].

Format:

Book

Contributor:

Davé, R. S. (Raju S.)

Loos, A. C. (Alfred C.)

Alumni and Friends Memorial Book Fund.

Series:

Progress in polymer processing

Language:

English

Subjects (All):

Plastics.

Polymeric composites.

Physical Description:

xviii, 480 pages : illustrations ; 25 cm.

Place of Publication:

Munich : Hanser Publishers ; Cincinnati : Hanser/Gardner Publications, [2000]

Summary:

Composites are said to be the "Materials of the Future". Advanced polymer composites are beginning to be used in down-to-earth structures such as bridges, buildings, and highways. The objectives of this book are to provide an overview of the fundamental principles underlying composite processing and to summarize the most important processes for composite manufacturing.

Contents:

Part I Theory

1 Chemistry, Kinetics, and Rheology of Thermoplastic Resins Made by Ring Opening Polymerization / Raju S. Dave, Kishore Udipi, Robert L. Kruse 3

1.2 Chemistry of Anionic Ring Opening Polymerization of Lactams 8

1.3 Kinetics of Anionic Polymerization of Caprolactam 10

1.3.1 Kinetics Model 10

1.3.2 Kinetic Model Verification 13

1.4 Viscosity Growth During Anionic Polymerization of Caprolactam 16

1.4.1 Viscosity Model 17

1.4.2 Viscosity Model Verification 17

1.5 Application of Rheo-Kinetics Modeling to Reaction Injection Pultrusion 22

2 Thermoset Resin Cure Kinetics and Rheology / Veronica M.A. Calado, Suresh G. Advani 32

2.1.1 Resins 33

2.1.2 Reinforcements 34

2.1.3 Manufacturing Process 35

2.1.4 Cure Cycles 35

2.1.5 Optimization 36

2.2 Cure Kinetics 37

2.2.1 Kinetic Models 38

2.2.2 Gelation Theory 41

2.2.3 Rheological Models 43

2.2.4 Diffusion Effects 46

2.2.5 Techniques to Monitor Cure 46

2.3 Effect of Reinforcements 51

2.4 Epoxy, Vinyl Ester, and Phenolic Resins 52

2.4.1 Epoxies 52

2.4.2 Vinyl Esters 54

2.4.3 Phenolics 69

2.5 The Coupled Phenomena 77

2.5.1 Resin Flow 77

2.5.2 Mass Transfer 79

2.5.3 Heat Transfer 80

2.6 Cure Cycles 92

2.7 Optimization and Control Strategies 94

2.7.1 Sensors 96

3 Phase Separation and Morphology Development during Curing of Toughened Thermosets / J.W. Park, S.C. Kim 108

3.2 Phase Separation in Terms of Thermodynamics and Kinetics 109

3.3 Literature Review 111

3.4 Experimental 117

3.4.1 Materials 117

3.4.2 Blending and Curing Procedure 117

3.4.3 Phase Separation Behavior 118

3.4.4 Morphology 118

3.5 Results and Discussion 118

3.5.1 Phase Diagram 118

3.5.2 Morphology 119

3.5.3 Phase Separation Mechanism 119

3.5.4 Effect of Composition 131

3.5.5 Effect of Cure Temperature 134

4 In Situ Frequency Dependent Dielectric Sensing of Cure / David E. Kranbuehl 137

4.2 Instrumentation 140

4.3 Theory 140

4.4 Isothermal Cure 141

4.5 Monitoring Cure in Multiple Time Temperature Processing Cycles 145

4.6 Monitoring Cure in a Thick Laminate 148

4.7 Resin Film Infusion 151

4.8 Smart Automated Control 154

5 A Unified Approach to Modeling Transport of Heat, Mass, and Momentum in the Processing of Polymer Matrix Composite Materials / Bamin Khomami 158

5.2 Local Volume Averaging 159

5.3 Derivation of Balance Equations 161

5.3.1 Conservation of Mass 161

5.3.2 Conservation of Momentum 163

5.3.3 Conservation of Energy 165

5.4 Specialized Equations for Various Polymer Matrix Composite Manufacturing Processes 167

5.4.1 Resin Transfer Molding (RTM) 168

5.4.2 Injected Pultrusion (IP) 170

5.4.3 Autoclave Processing (AP) 177

6 Void Growth and Dissolution / J.L. Kardos 182

6.1.1 The Autoclave Process 183

6.1.2 Void Evidence 185

6.1.3 The General Model Framework 185

6.2 Void Formation and Equilibrium Stability 185

6.2.1 Nucleation of Voids 186

6.2.2 Void Stability at Equilibrium 187

6.3 Diffusion-Controlled Void Growth 190

6.3.1 Problem Definition 190

6.3.2 Model Development 191

6.3.3 Model Predictions for Void Growth 195

6.4 Resin and Void Transport 201

7 Consolidation during Thermoplastic Composite Processing / Alfred C. Loos, Min-Chung Li 208

7.2 Intimate Contact 212

7.2.1 Literature Review 213

7.2.2 Intimate Contact Model 215

7.2.3 Intimate Contact Measurements 222

7.2.4 Model Verification 224

7.2.5 Parametric Study 228

7.3 Interply Bonding 231

7.3.1 Healing Model 233

7.3.2 Degree of Bonding 235

8 Processing-Induced Residual Stresses in Composites / Scott R. White 239

8.2 Process Modeling 242

8.2.1 Cure Kinetics 242

8.2.2 Thermochemical Modeling 245

8.2.3 Residual Stress Modeling 250

8.3 Experimental Results 258

8.3.1 Elastic Model Corrrelation 259

8.3.2 Viscoelastic Model Correlation 260

8.4 Processing Effects on Residual Stresses 263

8.4.1 Cure Temperature 263

8.4.2 Postcure 264

8.4.3 Three-Step Cure Cycles 266

9 Intelligent Control of Product Quality in Composite Manufacturing / Babu Joseph, Matthew M. Thomas 272

9.2 Traditional Approaches Using SPC/SQC 273

9.3 Knowledge-Based (Expert System) Control 275

9.4 Model-Based (Model-Predictive) Control 278

9.4.1 Model-Predictive Control of Continuous Processes 278

9.4.2 Model Predictive Control of Batch Processes (SHMPC) 279

9.5 Models for On-Line Control 283

9.5.1 Categories of Models 283

9.5.2 ANNs as On-Line Quality Models for SHMPC 284

9.5.3 Applications to Autoclave Curing 285

Part II Process

10 Autoclave Processing / Andrew R. Mallow, Flake C. Campbell 295

10.2 Autoclave Processing Description 297

10.2.1 The Cure Cycle 297

10.2.2 Resin Viscosity and Kinetic Models 298

10.2.3 Resin Hydrostatic Pressure and Flow 299

10.2.4 Resin Flow Models 300

10.2.5 Experimental Studies 301

10.2.6 Caul Plates and Pressure Intensifiers 303

10.2.7 Net Resin and Low Flow Resin Systems 305

10.3 Voids and Porosity 306

10.3.1 Theory of Void Formation 306

10.3.2 Void Models 307

10.3.3 Resin and Prepreg Variables 307

10.3.4 Debulking Operations 308

10.3.5 Debulking Studies 309

10.4 Tooling 311

10.4.1 Part Thermal Response 311

10.4.2 Heat Transfer Models 313

11 Pultrusion / B. Tomas Astrom 315

11.2 Process Description 319

11.2.1 Equipment 319

11.2.2 Materials 323

11.2.3 Market 324

11.2.4 Process Characteristics 325

11.2.5 Key Technology Issues 327

11.2.6 Pultrusion of Thermoplastic-Matrix Composites 328

11.3 Process Modeling 329

11.3.1 How Can Modeling Help? 330

11.3.2 Previous Modeling Work 331

11.4 Matrix Flow Modeling 332

11.5 Pressure Modeling 335

11.5.1 Flow Rate-Pressure Drop Relationships 335

11.5.2 Pressure Distributions 337

11.5.3 Comparison Between Model Predictions and Experiments 337

11.5.4 Sample Model Applications 340

11.6 Pulling Resistance Modeling 343

11.6.1 Viscous Resistance 344

11.6.2 Compaction Resistance 345

11.6.3 Friction Resistance 345

11.6.4 Total Pulling Resistance 345

11.6.5 Comparison Between Model Predictions and Experiments 346

11.6.6 Sample Model Applications 349

11.7 Outlook 354

12 Principles of Liquid Composite Molding / B. Rikard Gebart, L. Anders Strombeck 358

12.2 Preforming 361

12.2.1 Cut and Paste 363

12.2.2 Spray-Up 364

12.2.3 Thermoforming 364

12.2.4 Weft Knitting 365

12.2.5 Braiding 365

12.3 Mold Filling 365

12.3.1 Theoretical Considerations 365

12.3.2 Injection Strategies 368

12.3.3 Mold-Filling Problems 372

12.4 In-Mold Cure 376

12.4.1 Fundamentals 376

12.4.2 Optimization of Cure 376

12.4.3 Cure Problems 378

12.5 Mold Design 380

12.5.1 General Design Rules 380

12.5.2 Mold Materials 381

12.5.3 Stiffness Dimensioning 382

12.5.4 Sealings 383

12.5.5 Clamping 384

12.5.6 Heating Systems 384

13 Filament Winding / S.C. Mantell, D. Cohen 388

13.2 Manufacturing Process 392

13.2.1 Winding Techniques 392

13.2.2 Fibers and Resins 393

13.3 Equipment 395

13.4 Cylinder Design Guidelines 396

13.5 Filament-Winding Process Models 398

13.5.1 Thermochemical Submodel 400

13.5.2 Fiber Motion Submodel: Thermosetting Matrix Cylinders 401

13.5.3 Consolidation Submodel: Thermoplastic Cylinders 404

13.5.4 Stress Submodel 406

13.5.5 Void Submodel 407

13.6 Filament-Wound Material Characterization 408

13.6.2 Test Methods 409

14 Dieless Forming of Thermoplastic-Matrix Composites / Alan K.

Miller 418

14.2 Dieless Forming Concept 420

14.3 Simulations, Shape Categories, and Forming Machine Concepts 422

14.4 Near-Term Demonstration Machine 426

14.5 Overcurvature

Observations and Model 428

14.6 Continuous Dieless Forming 430

14.7 Forming Arbitrary Curved Shapes Without Dies 435

15 Intelligent Processing Tools for Composite Processing / F. Abrams 442

15.2 The Batch Process Control Problem 443

15.3 Tools for Planning Process Conditions 445

15.3.1 Trial and Error 446

15.3.2 Design of Experiment 448

15.4 Statistical Process Control 450

15.4.1 Process Science 451

15.4.2 Analytical Models 453

15.4.3 Knowledge-Based Expert Systems 456

15.4.4 Artificial Neural Networks 457

15.4.5 Summary of Methods 457

15.5 Tools for Real-Time Process Control 458

15.5.1 Supervisory Controllers 459

15.5.2 Knowledge-Based Adaptive Controllers 461

15.5.3 Expert Systems 462

15.5.4 Qualitative Reasoning 463

15.5.5 Fuzzy Logic 465

15.5.6 Artificial Neural Networks 465

15.5.7 Analytical Models 466.

Notes:

Includes bibliographical references and index.

Local Notes:

Acquired for the Penn Libraries with assistance from the Alumni and Friends Memorial Book Fund.

ISBN:

1569902267

OCLC:

41137645