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Methods of Manufacture for Composite Materials in Infrastructure
Filament Winding and Pultrusion
CST Composites is a world leading filament winding and pultrusion technology company.The company was founded in 1995, manufacturing some of the world’s first high performance sailing masts.
CST Composites
CST Composites’ constant pursuit of innovative product solutions and adoption of new composite manufacturing and design technology, has seen the business successfully diversify into new markets including industrial, mining, infrastructure, transport, and aerospace.
CST Composites
CST Key Facts
• 3 facilities in Sydney Australia• 25+ employees• 6 filament winding machines, 3 pultrusion lines.• Manufactured >60,000 tubes.• 70% export• Multiple awards, including Premiers NSW Export & Endeavour Awards 2009.
• Largest user of carbon tow in Australia.• Main markets including Marine, Mining, Aerospace, Industrial, Automotive
Filament winding
• Laminating fibres over a rotating mandrel– Fibre angles anywhere from 90 degrees (hoop) to near 0 degrees (longitudinal)
Filament winding
Filament winding
• Straight or tapered along the length
Filament winding
• Any convex cross section, ie round, elliptical, square
Filament winding
Can be wet winding (through a resin bath) or towpreg –pre‐impregnated tow.
Similarly, slit tapes can be used
Filament winding – tape laying
Filament winding
Composite usually needs to be cured in an oven or autoclave.
Often the expansion of the tool is used to help release the part.
It can also helps consolidate and can straighten 90 degree windings by removing wrinkling.
Filament winding
Filament winding ‐ advantages
Advantages include;• Easily design for specific strength or stiffness• Repeatable products
Filament winding ‐ advantages
• No weak plane around the circumference (as with fabric wrapping)
• Generally better consolidation than fabric wrapping• Batch process, setup cost is not high
Filament winding ‐ disadvantages
Disadvantages include:• Rate of production limited by number of fibres in production at one time.
• Batch process, batch sizes limited by tooling availability.
• Preparation and secondary processing can be time consuming
Filament winding ‐ disadvantages
Outside surface finish much wider tolerance on dimension and roughness than pultruded part. (surface finish comparison)
Powerpoles
• E‐glass and epoxy powerpoles, designed for Australian market (picture)– Wet winding is favourable in this instance, as high volume, low margin product.
– Stiffness / strength requirement easily achieved with FRP.– UV stable resin– Tough, scratch‐resistant / vandalism proof– Colour matched to concrete
UOW FRP Tubing
Screen furlers
Industrial Rollers
Industrial Rollers
Pump Housings
Underground Ventilation Ducts
Housings for Geotechnical Equipment
Housings for Geotechnical Equipment
Aerospace – Canadarm (MDA + CSA)
Aerospace – Canadarm (MDA + CSA)
Aerospace – Canadarm (MDA + CSA)
Weather balloon research
Weather balloon research
Tibetan Trumpet Prop – Cirque du Soleil (Las Vegas)
Automotive
Filament winding ‐ design
FMEA – Failure mode and effects analysisStiffness driven – A, B, D stiffnes matrices (classical laminate theory)
Strength driven – need to use known maximum strain and raw material test data.
Filament winding ‐ design
Two composite parts the same size may have a completely different ultimate strength in any given direction.
Reasons for this include:• Fibre direction / ply layup (ordering of layers)• Fibre or resin strength or stiffness• Fibre / resin interaction (affecting ILSS)• Winding parameters – speed (ie voids introduced), bath
and ambient temperature (affecting final fibre volume), tension
• Cure parameters
Pulling fibre and resin through a heated die, to form a cured part in the profile of the die cross‐section.
Image courtesy of www.creativepultrusions.com
Pultrusion
Pultrusion
Wet bath or injection
Pultrusion
Pultrusion – advantages
Dimensionally accurate and repeatableLow cost for higher volumesHigh production rateNo secondary processing (usually)
Pultrusion ‐ disadvantages
High set up cost – tooling and infeedLess scope for error in productionPart size is limited due to the amount of fibre required and the force required to pull.
Structural Carbon Fibre Strip
Structural Carbon Fibre Strip
Structural Strip Testing
Fibreglass strip with Fireshield
NSM Bar
Bar for near surface mount (NSM) reinforcement
Marine Sail Battens
Pultruded Glass / Carbon I Beam
Mangrove boardwalk – Maroochy Shire – QLD
Composite I Beam
Louvres
Grating / decking
Image courtesy of www.creativepultrusions.com
Pulwinding
Spoolable Pipeline
Conclusions
FRP products are becoming more prevalent across all industries – a result of more cost effective materials and processes.Understanding of the material properties and how they can be used to make products is key to the growth of the industry.
Questions