Manufacturing and applications of structural sandwich components
01 Jan 1997-Composites Part A-applied Science and Manufacturing (Elsevier)-Vol. 28, Iss: 2, pp 97-111
TL;DR: In this article, the authors present a review of the commercially most common manufacturing techniques for sandwich components for structural applications, and a baseline for further research and development efforts in the field of sandwich manufacture.
Abstract: Techniques to manufacture sandwich components for structural applications are summarized and discussed in terms of processing steps, characteristics of both technique and manufactured components, and application examples. The emphasis is on the commercially most common manufacturing techniques, though less common processing routes are briefly discussed as well. The intentions of this review are twofold: first, the paper aims to provide a means of comparing available manufacturing techniques in terms of feasibility for a specific application; second, the paper aims to provide a baseline for further research and development efforts in the field of sandwich manufacture. A discussion of recent developments and future trends in terms of both materials and processing routes rounds up the paper.
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TL;DR: An overview of composite materials, their characterization, classification and main advantages linked to physical and mechanical properties based on the recent studies are presented in this article, where the conventional manufacturing techniques of composite and their applications are presented.
Abstract: Emerged in the middle of 20th century, composite materials are now one of the hotspot research topics in the modern technology. Their promising characteristics make them suitable for enormous applications in industrial field such as aerospace, automotive, construction, sports, bio-medical and many others. These materials reveal remarkable structural and mechanical properties such as high strength to weight ratio, resistance to chemicals, fire, corrosion and wear; being economical to manufacture. Herein, an overview of composite materials, their characterization, classification and main advantages linked to physical and mechanical properties based on the recent studies are presented. There, were presented the conventional manufacturing techniques of composite and their applications. It was highlighted the tremendous need to discovery new generation of composites that should incorporate the synthetic or natural materials by implementing new efficient manufacturing processes. In the combination of matrix and reinforcement materials, the use of natural materials as constituent are compulsory in order to obtain a complete material degradable as environmentally friendly.
349 citations
TL;DR: In this paper, the deformation mechanism of incremental sheet forming (ISF) is examined experimentally through forming specially prepared copper sheets, and the authors measured the strain distributions through the thickness of the sheets are measured for two configurations of ISF: two-point incremental forming (TPIF) and single point incremental forming(SPIF).
330 citations
TL;DR: In this article, the authors classified polymers for use in lightweight vehicle are classified into high performance polymers, polymers used for weight reduction, reinforced polymer composites, polymer sandwich panels, and polymer/metal hybrid systems.
Abstract: Weight reduction of vehicle is very important because vehicle weight directly affects energy consumption. Studies researching lightweight vehicle manufacturing process that use polymers are reviewed in this paper. Approaches reducing the weights of vehicles using polymers most frequently involve replacing ferrous and non-ferrous metals with polymers and increasing the specific strengths and rigidities of polymers. Researches into polymers for use in lightweight vehicle are classified into high performance polymers, polymers for weight reduction, reinforced polymer composites, polymer sandwich panels, and polymer/metal hybrid systems. A diverse range of polymer materials can be used to make vehicle components and the manufacturing methods required to produce and work those materials vary greatly. Shaping processes must be chosen according to the materials being used and the product design. Replacement of metal products with polymer materials in current vehicles is limited. Large amounts of lightweight materials, such as polymers, will be greatly used to construct newly developed vehicles, including electric and electric/hybrid vehicles.
182 citations
TL;DR: In this paper, a continuous carbon fiber 3D printer was used to produce composite composite core shapes with honeycomb, rhombus, rectangle, and circle core shapes as a single piece.
Abstract: Many modern aircraft components are made from carbon fiber reinforced polymer sandwich structures with two outer skins possessing high tensile and compressive strengths separated by a lightweight core that provides shear stiffness. However, the conventional manufacturing method involves a complicated and costly bonding process. This study used a continuous carbon fiber 3D printer to manufacture sandwich structures with honeycomb, rhombus, rectangle, and circle core shapes as a single piece. The functional properties of the sandwich structures were quantified by shape evaluations and three-point bending tests. Three-point bending tests showed maximum load and flexural modulus increased as effective density increased for all core shapes, but the rhombus core shape was the strongest. Because the mechanical properties depended on the core shape, continuous carbon fiber 3D printers can be used to flexibly design core shapes that satisfy the desired strength and stiffness.
150 citations
TL;DR: In this article, foam filled 3D integrated core sandwich composite laminates with and without additional face sheets were fabricated using vacuum assisted resin infusion molding process in multiple steps, and three samples were tested at each energy level.
147 citations
References
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Book•
31 Mar 1997
TL;DR: In this paper, the basics of flow in RTM processes are discussed and the requirements for the design of RTM tools and components are discussed. But the focus is on the preforming process of reinforced reinforcement manipulation and preforming.
Abstract: 1 RTM theory -- 1.1 The basics of flow in RTM processes -- 1.2 RTM theory -- References -- 2 Materials for RTM -- 2.1 Reinforcements -- 2.2 Resins for RTM -- 2.3 Binders -- 2.4 Core materials for RTM -- References -- 3 Reinforcement manipulation and preforming -- 3.1 Introduction -- 3.2 Deformation modes of composite reinforcements -- 3.3 Steps in the preforming process for bound reinforcements -- 3.4 Preforming equipment -- 3.5 Preforming tools -- References -- 4 RTM mould tool design -- 4.1 Introduction -- 4.2 Tooling materials -- 4.3 Requirements for the design of RTM tools -- References -- 5 Production engineering requirements -- 5.1 Working environment -- 5.2 Specific requirements -- 6 Component design for RTM -- 6.1 Specific design features -- References -- 7 Flexible tool RTM -- 7.1 Materials -- 7.2 Materials handling -- 7.3 Tooling design for large area RTM -- Reference -- 8 Thick section RTM -- Reference -- 9 Known applications of RTM processing -- 9.1 Aerospace and defence -- 9.2 Automotive uses -- 9.3 Construction -- 9.4 Electrical and electronic -- 9.5 Industrial and mechanical -- 9.6 Marine -- 9.7 Sports equipment -- 9.8 Transportation -- 10 Troubleshooting RTM processing problems -- Reference -- 11 Suggestions for good practice in the design and development of RTM components -- 12 Costing -- 12.1 Top down costing -- 12.2 Outline costing -- 12.3 Production costing -- Reference -- 13 Quality control/assurance -- 13.1 Documentation requirements -- 13.2 Process control and process monitoring -- 13.3 Specimen documents -- 14 Case study -- 14.1 Introduction -- 14.2 Preform design and tooling -- 14.3 Mould tool design -- Appendix A brief word about patents -- Reference.
108 citations
TL;DR: In this paper, Dowty's experience in the composite technology areas of designing in composites, materials development, manufacturing using the resin transfer molding process, quality assurance and certification has underpinned the highly successful application of composites in advanced propeller blades.
40 citations
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28 citations
Patent•
19 Dec 1988TL;DR: A fiber reinforced plastics as discussed by the authors comprises a resin and chopped strands dispersed in the resin, wherein the chopped strands comprise glass fiber chopped strands composed of cut assemblies of glass filaments and high elastic chopped strands consisting of cut assembly of high modulus inorgtanic filaments having higher elastic modulus than the filaments, having 3000 or less number of assembled filaments.
Abstract: A fiber reinforced plastics comprises a resin and chopped strands dispersed in the resin, wherein the chopped strands comprise glass fiber chopped strands composed of cut assemblies of glass filaments and high elastic chopped strands composed of cut assemblies of high modulus inorgtanic filaments having higher elastic modulus than the filaments and having 3000 or less number of assembled filaments. By this arrangement, the both chopped strands are closely and uniformly dispersed in the resin and the force interaction between the both chopped stands are enhanced. The resultant plastics has remarkably improved strength and fatigue durability, and higher rigidity than conventional ones.
27 citations
Patent•
21 Oct 1987
TL;DR: In this article, a method of making a shape article from at least one integrated multi-layered sheet having excellent mechanical properties and being light in weight is proposed, which includes the steps of providing a thermoplastic synthetic material reinforced by a fiber mat on one side of a substantially flat sheet of thermoplastastic synthetic foam having a homogeneous structure.
Abstract: A method of making a shaped article from at least one integrated multi-layered sheet having excellent mechanical properties and being light in weight, which includes the steps of providing a thermoplastic synthetic material reinforced by a fiber mat on at least one side of a substantially flat sheet of thermoplastic synthetic foam having a homogeneous structure, the fiber mat, thermoplastic synthetic material and sheet of synthetic foam being integrated under the influence of elevated temperature and increased pressure, providing deformability by entirely or locally heating the resulting integrated fiber reinforced sheet, giving the heated sheet the desired structure and shape, and fixing the article by cooling. The invention also includes a process starting from a sheet of a thermoplastic foam having a homogeneous structure having attached thereto at least one fiber mat impregnatd with a thermoplastic synthetic material, which includes the steps of providing deformability by entirely or locally heating the resulting integrated fiber reinforced sheet, giving the heated sheet the desired structure and shape, and fixed the article by cooling.
23 citations