Polymer matrix composites are finding increasing number of applications due to their high weight-saving potential as well as unique characteristics, such as high strength-to-density ratio, fatigue resistance, high damping factor, and freedom from corrosion. While many textbooks are available on the mechanics of polymer matrix composites, few cover their processing. Processing of Polymer Matrix Composites fills this gap. The book focuses on the major manufacturing processes used for polymer matrix composites and describes process details, process parameters and their effects on properties and process-induced defects, and analytical and experimental methods used for understanding process conditions. The book describes fibers, thermosetting and thermoplastic polymers, and interface characteristics that are important from the standpoint of both design and processing. It also emphasizes the applications of process fundamentals for both continuous fiber and short fiber polymer matrix composites. In addition the book considers quality inspection methods, tooling, and manufacturing costs and environmental and safety issues.
Chapter 1: Introduction
10.1 Constituents
10.2 Fiber Surface Treatment
10.3 Fiber Volume Fraction
10.4 Fiber Orientation Angle
10.5 Modulus and Strength of Unidirectional Composites
10.6 Laminated Structure
10.7 Thermal Properties
10.8 Manufacturing Processes
10.9 Cost Issues
10.10 References
Problems
Chapter 2: Fiber Architecture
2.1 Fiber Forms
2.2 Linear Fiber Architecture
2.3 Two-Dimensional Fiber Architecture
2.4 Three-Dimensional Fiber Architecture
2.5 Random Fiber Architecture
2.6 Selection of Fiber Architecture
References
Problems
Chapter 3: Matrix
3.1 Thermosetting Polymers
3.2 Thermoplastic Polymers
References
Problems
Chapter 4: Processing Fundamentals
4.1 Cure Cycle for Thermosetting Polymers
4.2 Viscosity
4.3 Fiber Surface Wetting
4.4 Resin Flow
4.5 Consolidation
4.6 Shrinkage
4.7 Voids
4.8 Residual Stresses and Distortions
4.9 Manufacturing Process Induced Defects and Their Detection
References
Problems
Chapter 5: Bag Molding Process
5.1 Prepreg
5.2 Bag Molding Process
5.3 Lay-Up Techniques
5.4 Automated Tape Laying
5.5 Cure Cycle
5.6 Thick Section Laminates
5.6 Out-of-Autoclave Curing
5.7 Sandwich Molding
5.9 Defects in Bag-Molded Parts
References
Chapter 6: Compression Molding
6.1 Sheet Molding Compound
6.2 Bulk Molding Compound
6.3 Compression Molding Process
6.4 Cure Cycle
6.5 Flow Pattern
6.6 Fiber Orientation
6.7 Defects in Compression Molded Parts
6.8 Compression Molding Parameters
6.9 Mold Design Considerations
6.10 Part Design Considerations
References
Chapter 7: Liquid Composite Molding
7.1 Resin Transfer Molding
7.2 Structural Reaction Injection Molding
7.3 High Pressure Resin Transfer Molding
7.4 Preforms
7.5 Resin Selection and Preparation
7.6 Processing Steps in Liquid Composite Molding
7.7 Mold Design
References
Chapter 8: Filament Winding
8.1 Filament Winding Process
8.2 Helical Filament Winding
8.3 Filament Winding Machines
8.4 Mandrel Material and Design
8.5 Filament Winding Process Parameters and Controls
8.6 Defects in Filament Wound Parts
8.7 Fiber Placement
8.8 Tube Rolling
References
Chapter 9: Pultrusion
9.1 Pultrusion Process
9.2 Pultrusion Production Line
9.3 Materials for Pultruded Products
9.4 Pultrusion Process Parameters
9.5 Design Guidelines for Pultruded Products
9.6 Processes Related to Pultrusion
References
Chapter 10: Forming of Thermoplastic Matrix Composites
10.1 Incorporation of Continuous Fibers in Thermoplastic Matrix
10.2 Consolidation of Thermoplastic Matrix Composites
10.3 Shape Forming
10.4 Forming Processes
10.5 Compression Molding
References
Chapter 11: Joining and Repair
11.1 Joining in Composites
11.2 Mechanical Fastening
11.3 Adhesive Bonding
11.4 Co-Curing
11.5 Joining of Thermoplastic Matrix Composites
References
Appendix A: Health and Safety Issues
Biography
Prof. P.K. Mallick is the William E. Stirton Professor of Mechanical Engineering at the University of Michigan-Dearborn. He received his M.S. and Ph.D. in Mechanical Engineering from Illinois Institute of Technology. His research focuses on polymers and composites, lightweight automotive materials, joining, and materials processing. Prof. Mallick has authored several books, including Fiber-Reinforced Composites: Materials, Manufacturing, and Design, 3rd Edition (CRC Press/Taylor & Francis). He is a Life Fellow of the American Society of Mechanical Engineers and a Fellow of the American Society for Composites.
"This book serves as a general introduction to students and researchers just entering the field and to scholars from other subfields seeking from basic to applicable information."
—Masami Okamoto, Toyota Technological Institute, Nagoya, Japan"I appreciate the focus on processing of polymer matrix composites. I think processing of materials in general has been somewhat neglected. Processing is really the key. Chapters 4 through 10 focus on a variety of processing techniques for polymer matrix composites. That would be my major attraction."
—K. K. Chawla, University of Alabama at Birmingham, USA