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Case Study of Composite Chassis Manufacturing Process Using Low Temperature Molds Tempered with Gradual Heat Annealing Process

Rządkowski Witold, Klik Przemysław, Tracz Jan, Kowalik Michał

Advances in Science and Technology. Research Journal

2022

Vol. 16, no 3

12--21

This case study describes a manufacturing process of composite chassis also known as monocoque. The structure is made using carbon fibre reinforced polymers (CFRP) which are manufactured in out-of-autoclave (OOA) process from pre-impregnated carbon fabrics and aluminium alloy honeycomb core. Since the material cost is high the aim of the project was to reduce the cost of manufacturing process i.e. cost of models and moulds. Therefore, instead of high-temp models and moulds a cheaper alternative was used. It consisted of Styrofoam models made using polyurethane (PU) paste and moulds made from CFRP using wet layup process which were cured at room temperature. Such moulds had to be adapted to withstand high temperatures during pre-preg cure. This was done with gradual heat annealing process which increased the maximum service temperature from 45C to 90C. This was enough for the low-temp cure of pre-preg material, but it might be possible to increase the temperature even further. As a result, the cost of manufacturing process had been reduced by 50%.

Analysis of VBO governing sequence to minimize porosity in out-of-autoclave prepregs

Shaik Feroz, Malkapuram Ramakrishna, Shekar K. Chandra, Varma Dhaval

Composites Theory and Practice

2021

R. 21, nr 3

87--95

The out-of-autoclave process is being used instead of the autoclave process due to its lower manufacturing costs to obtain products of the same quality. It is seen that in the out-of-autoclave, precure processes like compaction in the vacuum bag, the bagging sequence, vacuum pressure as well as the application time of vacuum are the major factors to produce acceptable quality parts, especially aero structure parts. In this study we will discuss how the bagging sequence, along with a change in the consumable materials, affects the final porosity. The void content for different bagging sequence conditions was analyzed by means of C-scan and microsection analysis on OOA prepreg laminates. It was noted that the bagging sequence and consumable materials may cause the porosity to be as low as ≈ 0.23% to as high as ≈ 4.24%.