1. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Fiber Reinforced Polymer, FRP (Composites) FRP ( 복합재료 )  Fiber( 섬유 ) + Plastic matrix ( 모재 ) Fiber: Kevlar, Glass fiber, Graphite fiber, Boron Plastic matrix: Epoxy, Polyester Process 1.Impregnation: fiber+resin 2.Molding –Compression molding –Vacuum bag molding –Open molding –Resin transfer molding http://vimeo.com/13769356

2. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Molding Reinforced Plastics Prepreg & Autoclave Vacuum bag molding Open molding (Contact molding) Resin transfer molding (RTM) Filament winding

3. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Prepreg Prepreg is a term for "pre-impregnated" composite fibers containing polymer matrix. The pre-preg are mostly stored in cooled areas since activation is most commonly done by heat. Pultrusion: http://www.youtube.com/watch?v=9tlQn5_cko0http://www.youtube.com/watch?v=9tlQn5_cko0 Prepreg: http://www.youtube.com/watch?v=Eq6Xj1UcIKghttp://www.youtube.com/watch?v=Eq6Xj1UcIKg Nesting: http://www.youtube.com/watch?v=y_TDd3bzDeMhttp://www.youtube.com/watch?v=y_TDd3bzDeM

4. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Typical Composite Process 1. Material preparation 2. Lay-up3. BAGGING4. CURE - Nesting - Core Machining - Metal preparation - ATL, AFP or Hand lay- up - Laser optical device - Vacuum check - Autoclave - Heat (rate, uniformity) - Pressure - Vacuum

5. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Typical Composite Process 5.DEBAGGING 6. CRD7. NDI8. Inspection - Cure log check - Appearance inspection -Trim the excess area - Ultra Sonic Inspection - Radio graphic Inspection - CMM - Inspector

6. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Equipment Auto Tape Layer HDF (Hot Drape Forming) NC Ply Cutter AutoclaveLaser Projector U.T C-scan

7. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Vacuum-bag molding Prepregs lay in mold and apply pressure in a vacuum. http://www.youtube.com/watch?v=sJlfzuxvESM Atmospheric pressure Clamping bar Vaccum trap Gel coat Gasket Vacuum trap Flexible bag Room temperature or oven cure hand or spray lay-up Mold release Resin and glass Mold © 갈창우, GNU

8. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Autoclave Hence, composite structures built of pre-pregs will mostly require an oven or autoclave to cure out. Temperature 180 °C, Pressure 600kPa, Time 3 h

9. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Sheet molding compound (SMC) & Compression Molding Compression molding: SMC is placed between two molds and pressure is applied. Sheet molding compound http://www.youtube.com/watch?v=IxaTwSBWz14http://www.youtube.com/watch?v=IxaTwSBWz14 SMC Compression Molded Composite

10. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Open-molding Open-molding process use single male or female mold and also called contact-molding Used in making products with high surface-area-to- thickness ratios. Hand lay-upSpray lay-up http://ma.gnu.ac.kr/vod/Plastic/FRP_Boat.MP4 http://www.youtube.com/watch?v=a7F5roYYvC8 http://www.youtube.com/watch?v=4Pw_tcgIiTQ

11. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Resin Transfer Molding (RTM) Resin Transfer Molding (RTM) allows the molding of components with complex shapes and large surface areas with a good surface finish on both sides. http://www.youtube.com/watch?v=1u-2GvhghQA

12. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Filament winding Glass fibers are embedded in thermosetting resin matrix materials and winded around a pipe. FRP pipe CNG tank http://www.youtube.com/watch?v=iOZl3v4RC18

13. © Pearson & GNU Su-Jin Kim Plastics Manufacturing Processes Composite Machining & Joining http://www.youtube.com/user/e1m1s#p/c/3B2C07E01F72869B/6/Kh_PO9O4BAs http://www.youtube.com/watch?v=Pi3MjF860fM