Vacuum bag moulding

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Vacuum bag moulding is the primary composite manufacturing process for producing laminated structures. It is common in the aerospace industry. [1]

Contents

Process

It utilizes a flexible film to enclose the part and seal it from the outside air. The vacuum bag material is accessible in a tube shape or a sheet of material. Then, a vacuum is drawn on the vacuum bag, and atmospheric pressure compresses the part during the cure. When a tube-shaped bag is used, the entire part can be enclosed within the bag. When utilizing sheet bagging materials, the edges of the vacuum bag are sealed against the edges of the mould surface to enclose the part against an air-tight mould. When bagged in this way, the lower mould is a rigid structure and the upper surface of the part is formed by the flexible membrane vacuum bag. The flexible membrane can be a reusable silicone material or an extruded polymer film. A vacuum is drawn on the part (and held) during cure after sealing the part inside the vacuum bag. This process can be fulfilled at either ambient or elevated temperature with ambient atmospheric pressure acting upon the vacuum bag. A vacuum pump is used usually to draw a vacuum. A cost-effective method of drawing a vacuum is with a venturi vacuum and air compressor. [2] [3]

Vacuum bag

It is built of strong rubber-coated fabric or a polymer film used to compress the part during cure or hardening. In some purposes, the bag encloses the entire material, or in other purposes, a mould is used to form one face of the laminate with the bag being a single layer to seal to the outer edge of the mould face. When using a tube-shaped bag, the ends of the bag are sealed and the air is drawn out of the bag through a nipple using a vacuum pump. Consequently, uniform pressure approaching one atmosphere is applied to the surfaces of the object inside the bag, holding parts together while the adhesive cures. The whole bag may be put in a temperature-controlled oven, oil bath or water bath and gently heated to accelerate curing.

Vacuum bagging is used broadly in the composites industry as well. [4] Carbon fibre fabric and fibreglass, along with epoxies and resins are popular materials laminated together with a vacuum bag operation.

Woodworking applications

Vacuum bags are used to laminate curved and irregular shaped workpieces in commercial woodworking facilities.

Polyurethane or vinyl materials are used to make the bag typically. A tube-shaped bag is open at both ends. The piece or pieces to be glued are placed into the bag and the ends sealed. One method of sealing the open ends of the bag is by placing a clamp on each end of the bag. A plastic rod is laid across the end of the bag, then, the bag is folded over the rod. A plastic sleeve with an opening in it is then snapped over the rod. This procedure forms a seal at both ends of the bag when the vacuum is ready to be drawn.

Sometimes, a "platen" is used inside the bag for the piece being glued to lie on. The platen has a series of small slots cut into it, to allow the air under it to be evacuated. The platen must have rounded corners and edges to restrict the vacuum from tearing the bag.

When a curved part is to be glued in a vacuum bag, the pieces being glued must be placed over a solidly built form, or have an air bladder placed under the form. This air bladder has access to "free air" outside the bag. It is used to create an equal pressure under the form, restricting it from being crushed. [5]

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<span class="mw-page-title-main">Injection moulding</span> Manufacturing process for producing parts by injecting molten material into a mould, or mold

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Compression molding is a method of molding in which the molding material, generally preheated, is first placed in an open, heated mold cavity. The mold is closed with a top force or plug member, pressure is applied to force the material into contact with all mold areas, while heat and pressure are maintained until the molding material has cured; this process is known as compression molding method and in case of rubber it is also known as 'Vulcanisation'. The process employs thermosetting resins in a partially cured stage, either in the form of granules, putty-like masses, or preforms.

Sheet moulding compound (SMC) or sheet moulding composite is a ready to mould glass-fibre reinforced polyester material primarily used in compression moulding. The sheet is provided in rolls weighing up to 1000 kg. Alternatively the resin and related materials may be mixed on site when a producer wants greater control over the chemistry and filler.

Out of autoclave composite manufacturing is an alternative to the traditional high pressure autoclave (industrial) curing process commonly used by the aerospace manufacturers for manufacturing composite material. Out of autoclave (OOA) is a process that achieves the same quality as an autoclave but through a different process. OOA curing achieves the desired fiber content and elimination of voids by placing the layup within a closed mold and applying vacuum, pressure, and heat by means other than an autoclave. An RTM press is the typical method of applying heat and pressure to the closed mold. There are several out of autoclave technologies in current use including resin transfer molding (RTM), Same Qualified Resin Transfer Molding (SQRTM), vacuum-assisted resin transfer molding (VARTM), and balanced pressure fluid molding. The most advanced of these processes can produce high-tech net shape aircraft components.

Vacuum Assisted Resin Transfer Molding (VARTM) or Vacuum Injected Molding (VIM) is a closed mold, out of autoclave (OOA) composite manufacturing process. VARTM is a variation of Resin Transfer Molding (RTM) with its distinguishing characteristic being the replacement of the top portion of a mold tool with a vacuum bag and the use of a vacuum to assist in resin flow. The process involves the use of a vacuum to facilitate resin flow into a fiber layup contained within a mold tool covered by a vacuum bag. After the impregnation occurs the composite part is allowed to cure at room temperature with an optional post cure sometimes carried out.

Transfer molding is a manufacturing process in which casting material is forced into a mold. Transfer molding is different from compression molding in that the mold is enclosed rather than open to the fill plunger resulting in higher dimensional tolerances and less environmental impact. Compared to injection molding, transfer molding uses higher pressures to uniformly fill the mold cavity. This allows thicker reinforcing fiber matrices to be more completely saturated by resin. Furthermore, unlike injection molding the transfer mold casting material may start the process as a solid. This can reduce equipment costs and time dependency. The transfer process may have a slower fill rate than an equivalent injection molding process.

A Lay-Up process is a moulding process for composite materials, in which the final product is obtained by overlapping a specific number of different layers, usually made of continuous polymeric or ceramic fibres and a thermoset polymeric liquid matrix. It can be divided into Dry Lay-up and Wet Lay-Up, depending on whether the layers are pre-impregnated or not. Dry Lay-up is a common process in the aerospace industry, due to the possibility of obtaining complex shapes with good mechanical properties, characteristics required in this field. On the contrary, as Wet Lay-Up does not allow uni-directional fabrics, which have better mechanical properties, it is mainly adopted for all other areas, which in general have lower requirements in terms of performance.

The main stages of the Lay-Up process are cutting, lamination and polymerization. Even though some of the production steps can be automated, this process is mainly manual, leading to laminates with high production costs and low production rates with respect to other techniques. Hence, nowadays, it is mainly suitable for small series production runs of 10 to 1000 parts.

Pressure bag moulding is a process for moulding reinforced plastics. This process is related to vacuum bag molding.

Autoclave moulding is an advanced composite manufacturing process.

References

  1. "Vacuum Bag - an overview | ScienceDirect Topics". www.sciencedirect.com. Retrieved 2021-01-15.
  2. "Vacuum Bag Molding – Closed Molding". CompositesLab. Retrieved 2020-11-10.
  3. "Vacuum bag moulding – CSIR – NAL". www.nal.res.in. Retrieved 2020-11-10.
  4. "Vacuum Bagging Machine". Vacuum Machines. 2018-09-20. Retrieved 2020-10-31.
  5. "Vacuum Bags For Woodworking". Archived from the original on 2010-09-28.