The common composite manufacturing process mainly involves four basic steps: Impregnation, Lay-up, Consolidation and Solidification. The above four steps are used in all composite production. Very common, but the sequence of operations may vary by application area and specific manufacturing process.
01 Impregnation
During the impregnation process, it is necessary to coat the resin on the dry reinforcement fibers and ensure that the fibers are fully saturated during the impregnation process. The product after the impregnation process is finished is called a laminate. Thorough and uniform impregnation can be achieved using different methods, automation is by far the most common method, and pressure rollers are usually used to ensure an even flow of resin through the fibers.
In the filament winding process, the fibers are impregnated through a resin bath. In the hand lay-up process, materials that have already been impregnated by the material supplier in a certain environment are used. During automatic fiber placement, this step is done on the impregnation line, and the impregnated product is called prepreg.
02 Layer
During the layup process, composite laminates are formed by placing fibers in the desired location and orientation and impregnating them, or by placing an already combined fiber/resin prepreg in the desired location and orientation. The thickness of the composite part is achieved by placing different layers of material.
In filament winding, the desired fiber distribution is obtained by the relative movement of the mandrel and carriage unit. Fibers have directional strength, and the directional orientation of the fibers directly affects the strength of the final part, so it must be placed in a specific fiber direction either manually or by an automated fiber placement system.
In the RTM process, dry preforms are placed in forming molds for infusion. Preforms are made from weaving, AFP, cutting and mating, etc., then infused with resin and cured to form laminates.
03 Consolidation
During consolidation, the purpose of applying pressure is to obtain the overall structure from the discrete layers, while removing voids and volatiles, to obtain the desired fiber volume fraction in the part, and to obtain the correct dimensional tolerances. This pressure can be achieved by vacuuming, compacting, pressing or wrapping. Vacuum is the most common method of consolidation used in the manufacture of most epoxy resins.
In the AFP process, consolidation is applied while paving using compaction rolls. In RTM, consolidation occurs during immersion in the press. In filament winding, a consolidating force is applied while winding, and then by winding with a thin plastic film under tension.
04 Curing
The final step is curing, which can take less than a minute for thermoplastics and up to 120 minutes for thermosets. Maintain vacuum or positive pressure, or both, during this time.
In thermoset composites, the cure rate depends on the resin formulation and cure kinetics. Providing heat during the curing process speeds up the curing of the resin. For thermoset resins, the higher the curing temperature, the faster the crosslinking process, but for best results, careful attention to the material data sheet is necessary.
Product description:
A2 fireproof aluminum composite panel is a new style non-combustible decoration material, which is using non-combustible inorganic materials as the core material and coated aluminum panel as surface (also can be copper, steel and other metal panel). Adopts advance fechnology to make it combination,then form a new kind stylish appearance, superior performance, convenient constuction indoor and outdoor decortion materials.The A2 fireproof panel can be widely used in all kinds of building interior and exterior decoration.
1. Incombustible inorganic material and metal panel perfectly combine the advantages of strength, flexibility, fire proof , moisture-proof， heating insulation, sound insulation.
2. Superior fireproof performance. In the combustion test, no fire spread,no halogen,no smoke, no toxic, no drip, no radiation, these all can prove unparalleled safety performance, meanwhile the product has green environment feature.
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