Manufacturing of Green Composites

GREEN COMPOSITES
Manufacturing Technologies
Methods of Manufacturing Composites
• Filament winding
• Lay-up methods
• Resin transfer moulding
• Injection moulding
• Vacuum bonding
• Autoclave bonding.
Filament Winding
• Filament winding is a process is which continuous
fiber (either pre-pregnated with resin, or coated
during winding) are pulled from a large spool and
wound on to a rotating mandrel after sufficient layers
have been built up the wound form is curved and the
mandrel removed.
• The parts most commonly made by this method are
cylindrical pipes, drive shafts, portables air raft water
tanks, spherical pressure tanks and yacht masts.
Lay-up Methods
• Layers of prepreg fabrics are built upon a mould,
in unidirectional or multi axial form. They are
then subjected to’ a consolidating force and cure
them.
• The process can be done either by hand, or by
automated lay-up which decreases the
manufacture time significantly.
• Complicated shapes can be credited in this way.
Resin Transfer Bonding
• In this method, dry reinforcement fiber is held in
a closed mould, and then resin is pumped
through the mould at high pressure.
• This is a more time-consuming process, as it
involves labour intensive preparation and lay-up.
• it has many advantages, as the mould is closed,
harmful emissions are reduced and a void-free
laminate and complex parts can be created in
this method.
Injection Molding
• This process is basically used for the production of plastic components, but this
method
• is also used to fabricate natural fibers. Schematic of injection molding is shown in
Figure.
• In this process, short fibers in the form of particles or powder are used
Vacuum Bonding
• In vacuum bonding, the composite (usually large
sandwich structures) is first placed over a mould
then a vacuum bay is placed over the top, the air is
removed from the vacuum, which forces the bag
down onto the lay-up with a pressure of 1 bar.
• The whole assembly is then placed inside an oven to
cure the resin, and the material is produced in a
relatively short time.
• This method is used in conjunction with either
filament winding or lay-up techniques.
Autoclave Bonding
• An autoclave is a pressure vessel, which controls exact
pressure temperature and vacuum conditions.
• The technique is very similar to that of vacuum
bonding except that the over is replaced by an
autoclave.
• This means that wring condition can be controlled
accurately to give high quality composites for a
specific purpose.
• The process takes much longer than others, and is
relatively expensive.
Three Layer Particle Board
• Particleboard is manufactured by mixing wood particles or flakes
together with a resin and forming the mix into a sheet.
• The raw material to be used for the particles is fed into a disc
chipper between four and sixteen radially arranged blades.
• The particles are first dried, after which any oversized or undersized
particles are screened out.
• Resin, in liquid form, is then sprayed through nozzles onto the
particles.
• There are several types of resins that are commonly used.
• Urea formaldehyde resin is the cheapest and easiest to use. It is
used for non-water-resistant boards.
• Melamine formaldehyde resin is significantly more expensive.
• Phenol formaldehyde is also fairly expensive. It is dark colored and
highly durable.
• These resins are sometimes mixed with other
additives before being applied to the particles, in
order to make the final product waterproof,
fireproof, insect proof, etc.
• Once the resin has been mixed with the particles,
the liquid mixture is made into a sheet.
• A weighing device notes the weight of flakes, and
they are distributed into position by rotating rakes.
• In graded density particleboard, the flakes are
spread by an air-jet which throws finer particles
than coarse ones.
• Two such jets, allow the particles to build up from fine
to coarse and back to fine.
• The sheets formed are then cold-compressed to reduce
their thickness and make them easier to transport.
• Later, they are compressed again, under pressures
between two or three mega pascals and temperatures
between 140°C and 220°C. This process sets and
hardens the glue.
• All aspects of these process must be carefully
controlled to ensure the correct size, density and
consistency of the board.
• The boards are then cooled, trimmed and sanded.
Bamboo Composite Board
• This method is adopted for manufacturing of a particleboard
with the bamboo fiber.
• This technique is the most suitable for processing such hard
fibers.
• The steam-exploded fiber is agitated using home-use mixer
and flocculent fiber along with PLA resin (dispersion type) is
mixed and dried at a temperature of 70 C for about 15 hours.
• And finally, hydraulic pressing is done at a temperature of 180
C for 10 minutes.
• The similar process is followed with various fibers such
as banana fiber and bagasse and so on.
• But depending upon the fiber used, the time of drying and
pressing will vary.
Methods Of Fabricating Soy Protien and Natural Fibre
Composite
Resin process
Composite process
Tensile Properties of Ramie Fiber Reinforced
SPC Unidirectional Composite (65% fiber content)
*Figures in parentheses are CV%

Tensile and Flexural Properties of Kevlar® and High
Strength Cellulose Fiber based
‘Advanced Green Composites’
Note : Fiber content of all specimens is 44% by wt.

Manufacturing of Green Composites

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Manufacturing of Green Composites

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GREEN COMPOSITES

*Figures in parentheses are CV%

Note : Fiber content of all specimens is 44% by wt.

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