A modified pultrusion process

Irfan, Muhammad Shafiq; Shotton-Gale, N.; Paget, MA; Machavaram, Venkata R.; Leek, Colin; Wootton, Shane; Hudson, M. K.; Helsmans, Stefan; Bogonez, Francisco Nieves; Pandita, Surya D.; Fernando, Gerard Franklyn

doi:10.1177/0021998316666653

Cited by 14 publications

(14 citation statements)

References 14 publications

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“…[8][9][10][11] A different set of modifications, referred to as 'clean filament winding', have also been reported in detail. [12][13][14][15][16][17] The reduction of waste (resin, solvent) and fewer emissions to the atmosphere are emphasized in these works. The resin bath is replaced with a combination of a resin impregnation unit and spreading stations for tow bundles.…”

Section: Filament Windingmentioning

confidence: 99%

The effect of processing on the microstructure of hoop-wound composite cylinders

Lasn

Mulelid

2020

Journal of Composite Materials

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Fibre-reinforced polymer composites are increasingly used to make pipes and pressure vessels. The relationship between wet-winding manufacturing, composite microstructure, and the mechanical performance is complex due to many process parameters and material properties involved. Efficient manufacturing aspirations however drive process innovations that include new, radically different tow impregnation methods. In this work, the process–property–performance relationship is experimentally construed for hoop-wound carbon fibre/epoxy composite cylinders. The difference between cylinders produced by a new tow impregnation system and cylinders from the reference impregnation system was investigated. Winding speed and cylinder wall thickness were considered as two additional variables. The results indicate that, within current scope, composite microstructure is relatively insensitive to the winding speed and to final cylinder thickness. Meanwhile, un-optimized changes for tow impregnation affect the void content, the size distribution of voids and the interlaminar failure mode in short beam shear.

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Section: Filament Windingmentioning

confidence: 99%

The effect of processing on the microstructure of hoop-wound composite cylinders

Lasn

Mulelid

2020

Journal of Composite Materials

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“…1,2 The details of this unit were presented previously. 32 The array of fibres are directed under the resin impregnation unit-(b) where the partially spread fibres are impregnated at the resin delivery head-(c). In the modified pultrusion technique, the drip tray that is used with conventional pultrusion is replaced by an inclined and integrated platform that serves as the resin-drip tray and the fibre compaction zone-(d), before the fibres are directed to the heated die.…”

Section: Description Of the Modified Low-pressure Impregnation Pultrumentioning

confidence: 99%

“…The theoretical basis for the design of the impregnator unit, including an assessment of the different modes of impregnation as a function of specified processing parameters, was detailed in reference. 32 Hence, only a summary is presented here. The modes of impregnation at the zones indicated in Figure 3 are summarised in Table 1 along with the relevant equations that were used to calculate the degree of impregnation.…”

Section: Design Calculations For the Impregnation Unitmentioning

confidence: 99%

“…The current authors reported previously on a modified pultrusion process 32 where the resin bath was replaced with a purpose-designed low-pressure resin impregnation unit. In summary, with reference to the mode of operation of the modified pultrusion technique, the resin and hardener are stored separately and pumped on demand via a pair of precision gear pumps to a static mixer.…”

Section: Introductionmentioning

confidence: 99%

“…Firstly, it was to demonstrate that the modified pultrusion equipment could be retrofitted on an industrial pultrusion machine without requiring any modification to the original machinery. Secondly, since unfilled resins were used in the laboratory trials, 32 it was necessary to demonstrate that filled resins could be used with this modified pultrusion technique in an industrial setting. Thirdly, it was necessary to demonstrate that the physical and mechanical properties of composites manufactured using the modified pultrusion technique did not result in any degradation of the physical, mechanical and thermo-mechanical properties.…”

Section: Introductionmentioning

confidence: 99%

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On-site evaluation of a modified pultrusion process: Fibre spreading and resin injection-based impregnation

Irfan

Harris

Paget

et al. 2020

Journal of Composite Materials

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The focus of the current research was to demonstrate a modified pultrusion technique at an industrial site using a commercial production machine. In this instance, the conventional resin bath was replaced by a custom-designed compact impregnation unit. The dimensions of the impregnator were 310 mm × 400 mm × 9 mm. The relatively short length of the impregnator, when compared to a 5 litre resin bath, meant that it had to be efficient in impregnating the reinforcing fibre bundles. This was achieved using a fibre spreading unit and a facility to inject the resin under low-pressure. The design basis for the fibre spreading unit and the impregnator are presented along with the methodology that was used to select the pultrusion speed and die temperature. The pultrusion experiments were performed using filled and unfilled vinyl ester resin and E-glass fibres. The profile of the 0.5 metre-long die was rectangular with dimensions of 32 mm × 2.2 mm. The fibre spreading unit and the impregnator were retrofitted to the pultrusion line with ease. The physical, mechanical and thermo-mechanical properties were determined for the pultruded composites using the resin bath and the modified technique. The properties of the latter were found to be equivalent or marginally superior when compared to the resin bath-based production method. However, in the modified pultrusion technique, when compared to conventional resin bath-based pultrusion, the volume of waste resin generated was 97% lower. The volume of solvent required to clean the equipment after production was reduced by 90%.

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An overview on current manufacturing technologies: Processing continuous rovings impregnated with thermoset resin

et al. 2021

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The demand for products made of fiber‐reinforced polymer composites (FRPC) is constantly growing. These lightweight products are characterized by high stiffness, high tensile strength, and high service life. FRPC processes that employ thermoset‐impregnated continuous rovings are easily automated and provide the products with the highest unidirectional tensile strength. A critical disadvantage of continuous fiber‐reinforced polymers is caused by relatively high production costs. Among others, three main factors contribute to these production costs: (1) material costs, especially when carbon fibers are used, (2) costs for manufacturing semi‐finished products, such as textiles or preimpregnated fabrics, and (3) costs for waste occurring along the entire chain of process steps. In this context, one group of processes shows outstanding characteristics: processes in which rovings are in situ impregnated with a thermoset resin and then directly processed. Wet filament winding and pultrusion are the most popular but not the only representatives of this group. For all these processes, in situ impregnation is the key element, and various technologies have been developed for this purpose, each with its own unique fluid‐mechanical effects on rovings. A fundamental understanding of these effects is crucial to achieve products of the utmost quality. The paper at hand provides an overview of manufacturing processes that employ in situ impregnation of continuous rovings, specifically focusing on impregnation technologies. On this basis, phenomenological models describing the effects on the rovings during processing (impregnation, tension, and spreading) are reviewed.

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A modified pultrusion process

Cited by 14 publications

References 14 publications

The effect of processing on the microstructure of hoop-wound composite cylinders

The effect of processing on the microstructure of hoop-wound composite cylinders

On-site evaluation of a modified pultrusion process: Fibre spreading and resin injection-based impregnation

An overview on current manufacturing technologies: Processing continuous rovings impregnated with thermoset resin

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