Introduction
Composite materials have revolutionized various industries by combining distinct physical and chemical properties to create unique solutions tailored for specific applications. This introduction explores the fascinating evolution of composites, tracing their origins from ancient civilizations to modern advancements in manufacturing techniques. As we delve into the history and development of composite materials, we will also examine the challenges they address and the innovative processes used in their fabrication. From the pioneering use of plywood in ancient Mesopotamia to the cutting-edge technologies employed today, composite materials continue to enhance strength, durability, and performance across a wide range of applications. Join us as we explore the world of composites and their transformative impact on manufacturing and engineering.
What is a Composite?
A composite material is formed by combining two materials that possess distinct physical and chemical properties. When combined, these materials have unique properties that make them ideal for specific tasks, such as increasing strength, reducing weight, enhancing electrical resistance, and/ or improving tribological properties. They also have the ability to enhance strength and stiffness, as well as thermal properties. One of the main advantages of using these materials is their ability to enhance the properties of the base materials, making them suitable for a wide range of applications. Before diving into molding processes, let's take a moment to reflect on the fascinating evolution of composite materials.
History of Composites
The ancient Mesopotamians were pioneers in utilizing composite materials, as they ingeniously bonded wood strips at various angles to produce plywood as early as 3400 B.C. Throughout history, various civilizations have ingeniously utilized the combination of natural resources around them to construct their homes, employing materials such as mud, straw, wood, and clay.
Between 1870 and 1890, the first synthetic resins capable of transforming from liquid to solid through polymerization were created. These polymer resins undergo a transformation from a liquid state to a solid state through the process of crosslinking the molecules.
In 1907, Leo Hendrik Baekeland, a chemist, introduced Bakelite, a groundbreaking synthetic resin that marked the beginning of the modern era of composites. The resin was very fragile, but Baekeland discovered a way to make it more flexible and durable by mixing it with cellulose. In 1917, Bakelite found its initial application in the production of gearshift knobs for Rolls Royce automobiles. In the 1920s and 1930s, there were significant advancements in the production of resins. In the late 1930s, a groundbreaking process was developed by the Owens-Illinois Glass Company. This process involved drawing glass into thin strands or fibers, which were then skillfully woven into a textile fabric. These innovative glass fibers, when combined with advanced synthetic (polyester) resins, resulted in the creation of composites that are both durable and lightweight.
From 1939 to 1945, the composites industry saw significant growth as the military sought lightweight materials with enhanced strength, durability, and resistance to weather conditions and corrosion from salt air and water. In 1945, more than seven million pounds of fiberglass were utilized, mainly for military purposes. Over time, the public sector began to recognize the numerous advantages of fiber-reinforced polymer (FRP) composites, particularly their exceptional resistance to corrosion. Introduced in 1948, fiberglass pipe quickly gained popularity in the oil industry due to its excellent corrosion resistance.
Composites experienced significant growth following the war and saw a rapid expansion throughout the 1950s. Various products such as boats, trucks, sports cars, storage tanks, pipes, and ducts were constructed using composites. In 1953, the first production Chevrolet Corvette with fiberglass body panels was manufactured. In the early 1950s, various manufacturing methods emerged, including pultrusion, vacuum bag molding, and large-scale filament winding. Filament winding played a crucial role in the development of the large-scale rocket motors that drove space exploration in the 1960s and beyond.
Composites are now being specified by many industrial designers and engineers for various components in industries such as aerospace, energy, semiconductors, manufacturing, construction, and transportation. Composites have made significant progress over the years.
What Challenges Can Composites Solve?
Custom composite materials address complex challenges that cannot be solved by any single material alone. Critical applications, standard elastomeric or polymer sealing solutions cannot deliver the required chemical properties from a homogeneous material. Therefore, a quality sealing solution provider will offer a material portfolio which includes various blended, laminated, wound, or infused composites to address these challenges.
Composites are precisely designed and manufactured to meet specific combinations of application or performance criteria such as strength-to-weight ratios, durability, wear resistance, impact on mating surfaces, or resistance to specific environmental conditions.
Composite materials have gained popularity in manufacturing due to the extensive selection of polymers and other materials that a diverse range of industries can utilize.
Composites combine different materials and blends that fortify that material for its critical application, often enhancing the final properties (for example, increased durability, improved tribology, superior corrosion resistance, improved flexibility, and much more).
Composite molding involves the utilization of composite materials, which are shaped and molded during the manufacturing process.
Do you have an interest in delving deeper into the composite manufacturing process? Keep reading to find out more.
Exploring the World of Composite Materials
As mentioned earlier, composite manufacturing involves the utilization of composite materials. Composite materials are created through the combination of various substances, often polymers, to form a cohesive whole.
Different techniques are used in the production of these materials. Now, let's explore the various methods employed in composite fabrication.
Understanding Filament Winding
One crucial aspect of filament winding involves the incorporation of fiber tape or filament tape into the resin, which serves to enhance its strength. The tape already wetted (impregnated) with the resin is then used on a fiber placement or filament winding machine to produce the product.
Hand Layup
The hand layup method of composite fabrication involves using pre-impregnated woven fabrics or mats cut into smaller pieces and shapes.
Tape Laying
Tape laying is comparable to the process of hand layup fabrication. The process involves layering strips of fabric with resin to create a composite material. The orientation of the individual layers provides the desired strength in the critical directions after being molded.
Injection Molding
Injection molding is a manufacturing process that involves injecting molten material into a mold to create a desired shape. It is a widely used technique in various industries, including aerospace, upstream, midstream, and downstream energy, as well as water filtration. The process allows for the production of complex and precise parts with high efficiency and repeatability. Injection molding involves the use of heated polymers and polymer composites, which are injected into a mold to create the desired shape.
Compression Molding
Compression molding is a manufacturing process that involves compressing a material into a specific shape using heat and pressure. During compression molding, a preheated material is placed into a mold cavity and then compressed to form the desired shape. For PTFE specifically, the material is compressed without heating.
Melt Molding
Melt molding is a manufacturing process that involves compressing a material into a specific shape using heat and pressure. During the process, the material is placed in a mold cavity, heated to a temperature above its melting point, and then compressed to form the desired shape.
How Can CDI Composites Help Solve Your Problem?
Our advanced materials portfolio includes:
To ensure seamless integration and superior performance of these materials, we have mastered various bonding processes:
We have only touched the surface of the many applications and options available with composite solutions. With custom engineering, material design, and manufacturing to specifications, CDI can partner with our customers to create the perfect solution to the most demanding challenge. Contact us today to learn more about the wonderful world of composites and how we can lend a hand.