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AMTS-SWP-0014-A-2008
Reference Number:
AMTS_SWP_0014_2008
Date:
June 2008
Version:
A
Page 1 of 15
Wet Lay-Ups
AMTS-SWP-0014-A-2008
Contents
1
Scope .......................................................................................................3
Primary References.................................................................................3
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Wet Lay-Ups
AMTS-SWP-0014-A-2008
1 Technical Terms
2 Scope
This procedure describes the manufacturing procedure of wet lay-ups. The following
sections are discussed with reference to other SWPs, where applicable.
Materials used in wet lay-ups
Reinforcement (fibres used in the epoxy matrix)
Resins
Tools required
Moulds
Hand tools
Processing
Processing of epoxy resins
Method for producing a wet lay-up
Preparation of the mould
Lay-up method
3 Primary References
MIL-HDBK-17-1F: Composite Materials Handbook, Volume 1. Polymer Matrix
Composites Guidelines for Characterization of Structural Materials
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Wet Lay-Ups
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4.1 Reinforcement
The choice of a suitable reinforcing fibre depends mainly on the required application.
The criteria for selecting the reinforcing fibres are:
Density
Elasticity
Tensile strength
Impact strength
Cost
Property
E-glass
Aramid
Carbon
10
Density [g/cm]
2.5
1.4
1.8
70
100
210
2400
3000
4000
4.50%
2%
1.20%
Impact strength
Better
Best
Fair
Fatigue resistance
Good
Better
Best
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AMTS-SWP-0014-A-2008
4.2 Resin
The selection of a resin system depends on the required application.
The criteria for selecting the resin are:
Polyester Resins
Vinyl esters
Epoxies
5 Tools required
5.1 Moulds
Male or female moulds are used to produce the component depending on the finish
required. Female moulds are used whenever a smooth external finish is required
and male moulds for a smooth internal finish.
GRP
Wood (Superwood / MDF board, chipboard, plywood, solid wood)
Hard shell plaster
Metal
Silicone rubber moulding compounds
Prototyping board or polyurethane casting material
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AMTS-SWP-0014-A-2008
Fig 6.1 gives a flow diagram of the most common activities during a hand lay-up.
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Mould Preparation
Environmental Preparation
Preparation of Materials
Mixing of epoxy
Impregnation of layers
Vacuum bagging
Cleaning of tools
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To clean the mould, remove all left over epoxy and other materials after demoulding of the previously moulded part.
A simple piece of Perspex is an efficient tool for the removal of dried epoxy
from a mould. Care should be taken however not to damage the surface of
the mould during the cleaning process.
Filling all dents or holes in the mould with plasticine or a similar filling
product.
Flattening all bumps (including the plasticine) with fine sanding paper
to give a smooth finish to the surface.
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The optimal process conditions can be obtained by heating up the resin and
moulds.
Humidity:
The environment must be kept free of dust and dust emitting sources to
prevent contamination of the air.
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Gives the component its aesthetic exterior finish (smooth, coloured and
glossy).
Protects the laminate against moisture.
Protects the laminate against ultra-violet light.
Provides a product with enhanced chemical- and weather resistance.
Closes the pinholes in the GRP surface preparation time for further
processing (e.g. applying a paint layer) is significantly reduced. Without a
surface layer the GRP surface exhibits small pinholes that have to be filled up
before the surface can be painted or sprayed.
The type of material selected as surface layer depends on the required specification.
Existing gel coats include the following:
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AMTS-SWP-0014-A-2008
Position the first layer, making sure that the direction of filaments are
correct (The designer calculated the parts strength assuming that the
orientation of the fibres during manufacturing of the part will be correct.)
Dab the canvas (using a brush) against the mould to impregnate it using the
resin underneath.
When there is no more resin underneath the layer, new resin should be
applied. Do not keep the canvas too dry impregnating the next layer will
take longer than necessary; do not make it too wet excessive resin is not
removed easily!
Apply the second layer, impregnating it by using the resin from the previous
layer.
When there is no more resin underneath the layer, apply new resin
according to the aforementioned guidelines.
Apply the rest of the layers as described above.
When applying the last layer, only add resin if there is no resin remaining
from previous layers that can be used.
Useful hints:
Sometimes it is also difficult to determine whether a layer has been
impregnated completely. Glass and aramide fabrics change their colour,
glass changes from its original opaque white to a clear or greenish colour,
depending on the colour of the resin. This change in colour can be more
easily determined when applied on moulds with dark surfaces. Carbon
fibres do not change their colour, so their state of impregnation is extremely
difficult to determine. The only sign might be the vanishing gaps between
single fibres.
When trying to push up the fibre volume or fibre-to-resin fraction, always
keep in mind that a lay-up which has not been impregnated sufficiently will
break. A high fibre volume fraction is good to have but not at the expense
of strength due to layers which cannot connect to each other because one
of them has not been impregnated completely.
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By using a foam roller, the process can be made much more efficient, but
only makes sense for parts with a large surface area, e.g. skins for aircraft
wings.
Squeegees are used to spread the epoxy evenly over the entire area and
will remove air bubbles that may form between the layers.
Cleaning of tools:
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Warning: Acetone is extremely flammable with a low flash point. Containers for
acetone, especially when open may NOT under any circumstances be placed or
stored near open flames, where welding or grinding is in progress, smoking areas
or electrical switches.
6.11 De-moulding
After the part has cured sufficiently, it can be de-moulded. Care must be taken to
ensure the curing process has completed, as de-moulding forces may cause
damage to parts when the resin is still in a soft, semi-cured phase.
Select the most suitable technique for de-moulding. Refer to SWP010 on the Demoulding, Trimming and Machining of Composites.
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8 Quality control
The best measure of quality control is the repeatability of a process. If the same
conditions can be created uniformly throughout a process, the quality of the product
will mostly remain consistent. Improved consistency is achieved in an environment
where moisture and temperature is accurately controlled.
The surface of the test sample is scratched using a sharp object to determine
the shoe-hardness of the epoxy. Inconsistent scratch depth and surface
hardness indicates an incomplete reaction of the epoxy components. This is
caused as by inconsistent or incorrect mixing procedures.
The test sample will also indicate if the curing process is still incomplete.
These specimens can then be subjected to a destructive test to establish the quality
of the lay-up. The specimens must be assembled with the same epoxy batch mixture
and subjected to curing pressure, temperature and the time identical to the actual
part.
Refer to SWP001 on Test Specimens.
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Appendix 1:
Problems and remedies found in hand lay-ups
Problem
Possible Cause
Remedy
Insufficient amount of
catalysts added
Incorrect mixing
Resin not mixed properly.
Processing temperature
too high or too low.
Processing and curing
time too low.
Mouldings, filling
compounds or moulding
compounds burn up.
*Notes:
P E -
Polyester system
Epoxy system
Page 15 of 15
Notes*
P
E
P
E
P,E
P,E
E
P,E
P,E
P,E
P,E
P,E
P,E
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E
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