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復合材料知多少？
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更新日期： 2021-12-8 |
復合材料的原材料包括樹脂、纖維和芯材等有多種選擇，各種材料又有其獨特的強度、剛度、韌性和熱穩(wěn)定性等性能，成本和產(chǎn)量也不盡相同。然而，復合材料作為一個整體，其最終性能不僅與樹脂基體和纖維（以及夾芯材結構中的芯材）有關，而且與結構中材料的設計方法和制造工藝有密切聯(lián)系。
Composites are made from various raw materials including resins, fibers, core materials, etc. As they have different strength, stiffness, toughness, thermal stability and other performance, their costs and outputs are also different. However, the final performance of the composite as a whole is not only related to the resin matrix and fiber (and the core material in the sandwich structure), but also closely related to the structural design and manufacturing process.
十種常見復材成型工藝
10 Common composite forming processes
一、噴涂成型/
Spray molding
材料選擇
樹脂：主要為聚酯
纖維：粗玻璃纖維紗
芯材：需要單獨與層合板結合
Material options
Resin: polyester is mainly used
Fiber: thick glass fiber yarn
Core: needs to be combined with laminate separately
噴涂成型：把短切纖維增強材料與樹脂體系同時噴涂在模具內(nèi)，然后在常壓下固化成熱固性復合材料制品的一種成型工藝。
Spray molding: Chopped-fiber reinforced materials and resin systems are sprayed into the mold at the same time, and then cured into thermosetting composites under normal pressure.
典型應用：簡易圍欄，低載荷結構板，如敞篷車車身、卡車整流罩、浴缸和小型船艇
Typical application: simple fences, low-load structural panels, such as convertible bodies, truck fairings, bathtubs and small boats
二、手糊成型/
Hand paste molding
材料選擇
樹脂：無要求，環(huán)氧、聚酯、聚乙烯基酯、酚醛樹脂均可
纖維：無要求，但是基重較大的芳綸纖維難以手糊浸潤
芯材：無要求
Material options
Resin: no special requirement, epoxy, polyester, polyvinyl ester, phenolic resin are all desirable
Fiber: no special requirement, but hand paste molding and infiltration is difficult to achieve for aramid fiber with a larger basis weight
Core: no special requirement
手糊成型：手動將樹脂浸潤纖維，纖維可以為機織、編織、縫合或粘結等增強方式，手糊成型通常用滾輪或刷子完成，然后用膠滾擠壓樹脂使之滲入纖維。層合板置于常壓下固化。
Hand paste molding: The resin is manually infiltrated into the fiber. The fiber can be reinforced by mechanical weaving, manual weaving, stitching or bonding, etc. The hand paste molding process is usually completed with a roller or brush, and then the resin is squeezed into the fiber with a rubber roller. The laminate is cured under normal pressure.
典型應用：標準風電葉片，批量制作的船艇，建筑模型
Typical application: standard wind turbine blades, mass-produced boats, architectural models
三、真空袋工藝/
Vacuum bag molding
材料選擇
樹脂：主要為環(huán)氧和酚醛樹脂，聚酯和聚乙烯基酯不適用，因為它們含有苯乙烯，揮發(fā)進入真空泵
纖維：無要求，即使基重較大的纖維也可以在壓力下被浸潤
芯材：無要求
Material options
Resin: epoxy and phenolic resins are mainly used, polyester and polyvinyl ester are not applicable, because they contain styrene which volatilizes into the vacuum pump
Fiber: no special requirement, even fibers with a larger basis weight can be infiltrated under pressure
Core: no special requirement
真空袋工藝：真空袋工藝是上述手糊工藝的延伸，即在模具上封一層塑料膜將手糊好的層合板抽真空，給層合板施加一個大氣壓的壓力，達到排氣緊實的效果，以提高復合材料的品質。
Vacuum bag molding: It is an extension of the above-mentioned hand paste molding process, that is, a layer of plastic film is sealed on the mold to vacuumize the hand-pasted laminate, and an atmospheric pressure is applied to the laminate to achieve the effect of exhausting gas and then improve the quality of the composite material.
典型應用：大尺寸的游艇，賽車零部件，船舶制造過程中芯材的粘結
Typical application: bonding of core materials in large-size yachts, racing parts and shipbuilding processes
四、纏繞成型/
Filament winding
材料選擇
樹脂：無要求，如環(huán)氧、聚酯、聚乙烯基酯和酚醛樹脂等
纖維：無要求，直接使用線軸架的纖維束，不需要機織或縫織成纖維布
芯材：無要求，但蒙皮通常為單層復合材料
Material options
Resin: no special requirement, such as epoxy, polyester, polyvinyl ester and phenolic resin, etc.
Fiber: no special requirement, directly use the fiber bundle of the spool holder, no need to weave or stitch into fiber cloth
Core: no special requirement, but the skin is usually a single-layer composite material
纏繞成型：纏繞工藝基本用于制造中空、圓形或橢圓形結構件，如管道和槽。纖維束經(jīng)過樹脂浸潤后沿各種方向纏繞在芯軸上，工藝過程由纏繞機和芯軸轉速控制。
Filament winding: The winding process is basically used to manufacture hollow, round or oval structural parts, such as pipes and grooves. The fiber bundle is wound on the mandrel in various directions after being infiltrated by the resin, and the process is controlled by the winding machine and the speed of the mandrel.
典型應用：化學品儲藏罐和輸送管，氣缸，救火員呼吸罐
Typical application: chemical storage tanks and pipelines, gas cylinders, firefighter breathing tanks
五、拉擠成型/
Pultrusion molding
材料選擇
樹脂：通常為環(huán)氧、聚酯、聚乙烯基酯和酚醛樹脂等
纖維：無要求
芯材：未普遍使用
Material options
Resin: usually epoxy, polyester, polyvinylester and phenolic resin, etc.
Fiber: no special requirement
Core: not commonly used
拉擠成型：從線軸架抽出的纖維束浸膠后穿過加熱盤，在加熱盤完成樹脂對纖維的浸潤，并且控制樹脂含量，最終將材料固化成要求的形狀；這種形狀固定的固化產(chǎn)品被機械切割為不同長度。纖維也可以沿0度以外的方向進入熱盤。擠拉成型是一個連續(xù)的生產(chǎn)過程，制品截面通常有固定形狀，允許有微小變化。將通過熱盤的預浸潤材料固定并鋪入模具立即固化，雖然這樣的流程連續(xù)性較差，但可以實現(xiàn)截面形狀的改變。
Pultrusion molding: The fiber bundle drawn from the spool frame is dipped and passed through the heating plate, where the resin is infiltrated into the fiber and the resin content is controlled. Finally the material is cured into the required shape. The cured product with a fixed shape is mechanically cut into different lengths. Fiber can also pass through the heating plate in directions other than 0 degrees. Pultrusion is a continuous manufacturing process. The cross-section of the product usually has a fixed shape, allowing small changes. The pre-dipped material passing through the heating plate is fixed and laid into the mold to be cured immediately. Although this process has poor continuity, it can change thecross-sectional shape.
典型應用：房屋結構的梁和桁架，橋梁，梯子和圍欄
Typical application: beams and trusses of house structures, bridges, ladders and fences
六、樹脂傳遞模塑工藝/
Resin transfer molding
材料選擇
樹脂：通常為環(huán)氧、聚酯、聚乙烯酯和酚醛樹脂，雙馬來酰亞胺樹脂可以在高溫下使用
纖維：無要求?？p合纖維更適合此工藝，因為纖維束間隙利于樹脂傳送；有專門研發(fā)的纖維可以促進樹脂流動
芯材：蜂窩泡沫不適用，因為蜂窩單元將被樹脂充滿，壓力也會導致泡沫塌陷
Material options
Resin: epoxy, polyester, polyvinyl ester and phenolic resin usually used, bismaleimide resin can be used at high temperature
Fiber: no special requirement, stitched fibers are more suitable for this process, because the fiber bundle gap can help transfer the resin, specially developed fibers can promote resin flow
Core: honeycomb foam is not suitable, because the cells of the honeycomb structure will be filled with resin, and pressure will also cause foam collapse
樹脂傳遞模塑工藝：將干纖維鋪覆在下模內(nèi)，可以預先施加壓力使纖維盡量與模具形狀貼合，并予以粘合綁定；然后，把上模固定在下模上形成型腔，再將樹脂注入型腔。通常采用真空輔助樹脂的注入和對纖維的浸潤，即真空輔助樹脂注入工藝（VARI）。一旦纖維浸潤完成，即關閉樹脂導入閥，并將復合材料進行固化。樹脂注入和固化既可以在室溫下進行，也可以在加熱條件下完成。
Resin transfer molding: Lay dry fibers in the lower mold and apply pressure in advance to make fibers fit the mold shape as much as possible and bond them together. Next, fix the upper mold on the lower mold to form a cavity, and then inject the resin into the cavity. Generally, vacuum-assisted resin injection and fiber infiltration are used, that is, the vacuum-assisted resin injection process (VARI). Once the fiber infiltration is completed, the resin introduction valve is closed in order to cure the composite material. Resin injection and curing can be done at room temperature or under heating condition.
典型應用：小型而復雜的航天飛機和汽車零部件，火車座椅
Typical application: small and complex space shuttles and auto parts, train seats
七、其他灌注工藝/
Other infusion processes-SCRIMP, RIFT, VARTM
材料選擇
樹脂：通常為環(huán)氧、聚酯、聚乙烯酯樹脂
纖維：任何常見纖維?？p合纖維更適合此工藝，因為纖維束間隙加速樹脂傳送
芯材：蜂窩泡沫不適用
Material options
Resin: epoxy, polyester, polyvinyl esterresin mainly used
Fiber: any common fiber can be used. stitched fibers are more suitable for this process, because the fiber bundle gap accelerates the resin transfer
Core: honeycomb foam is not applicable
其他灌注工藝：將干纖維以類似于RTM工藝中的方式鋪覆，然后鋪上剝離布和導流網(wǎng)。鋪層完成后，用真空袋完全密封，在真空度達到一定要求時，將樹脂導入整個鋪層結構。樹脂在層合板中的分布依靠導流網(wǎng)引導樹脂流動來實現(xiàn)，最后自上而下將干纖維完全浸潤。
Other infusion processes:
Fabrics are laid up as a dry stack of materials as in RTM. The fiber stack is then converted with peel ply and a knitted type of non-structural fabric. The whole dry stack is then vacuum bagged, and once bag leaks have been eliminated, resin is allowed to flow into the laminate. The resin distribution over the whole laminate is aided by resin flowing easily through the non-structural fabric, and wetting the fabric out from above.
典型應用：試制小型船艇，火車和卡車的車身板，風電葉片
Typical application: trial production of body panels for small boats, trains andtrucks, wind turbine blades
八、預浸料-高壓釜工藝/
Autoclave prepreg processing
材料選擇
樹脂：通常為環(huán)氧、聚酯、酚醛樹脂，耐高溫樹脂如聚酰亞胺、氰酸酯和雙馬來酰亞胺也可使用
纖維：無要求。纖維束或纖維布均可
芯材：無要求，但泡沫需耐高溫高壓
Material options
Resin: epoxy, polyester, phenolic resins are usually used, high temperature resistant resins such as polyimide, cyanate ester and bismaleimide can also be used
Fiber: no special requirement, fiber bundle or fiber cloth is suitable
Core: no special requirement, but the foam needs to resist against high temperature and high pressure
預浸料-高壓釜工藝：纖維或纖維布由材料制造商使用含有催化劑的樹脂預先浸潤，制造方法為高溫高壓法或溶劑溶解法。催化劑為室溫潛伏型，使材料在室溫下有幾周或幾個月的有效期；冷藏條件可以延長其儲存期限。預浸料可以手工或機器鋪入模具表面，然后覆蓋真空袋，加熱至120-180°C。加熱后樹脂可以再次流動，并最終固化?？梢杂酶邏焊獙Σ牧鲜┘宇~外的壓力，通?？梢赃_到5個大氣壓。
Autoclave prepreg processing: The fiber or fiber cloth is pre-impregnated by the material manufacturer with a resin containing a catalyst, and the manufacturing process is conducted with the use of high temperature and high pressure method or solvent dissolution method. The catalyst is latent at room temperature, so that the material has a shelf life of several weeks or months at room temperature. Cold storage conditions can extend its shelf life. The prepreg can be placed on the mold surface by hand or machine, then covered with a vacuum bag and heated to 120-180°C. After heating, the resin can flow again and finally solidify. An autoclave can be used to apply additional pressure to the material, usually up to 5 atmospheres.
典型應用：航天飛機結構件（如機翼和尾部），F(xiàn)1賽車
Typical application: space shuttles’ structural parts (such as wings and tails), F1 racing cars
九、預浸料-非高壓釜工藝/
Out-of-autoclave prepreg processing
材料選擇
樹脂：通常僅環(huán)氧樹脂
纖維：無要求，與傳統(tǒng)預浸料一樣
芯材：無要求，但使用標準PVC泡沫需特別注意
Material options
Resin: usually only epoxy resin is used
Fiber: no special requirement, the same as traditional prepreg
Core: no special requirement, but the use of standard PVC foam requires special attention
預浸料-非高壓釜工藝：低溫固化預浸料制造工藝與高壓釜預浸料完全相同，不同的是樹脂的化學特性允許其在60-120°C實現(xiàn)固化。對于低溫60°C固化，材料的工作時間僅一周；對于高溫催化劑（>80°C），工作時間可達到幾個月。樹脂體系的流動性允許僅使用真空袋固化，避免使用高壓釜。
Out-of-autoclave prepreg processing: Low-temperature cure prepreg fabrication process is exactly the same as that of autoclave prepreg, except that the chemical properties of the resin allow it to be cured at 60-120°C. For curing at a low temperature of 60°C, the working time of the material is only one week. For a high-temperature catalyst (>80°C), the working time can reach several months. The fluidity of the resin system allows only the use of vacuum bags to cure, avoiding the use of autoclaves.
典型應用：高性能風電葉片，大型賽艇和游艇，救援飛機，火車部件
Typical application: high-performance wind turbine blades, large racing boats and yachts, rescue aircraft and train parts
十、半預浸料SPRINT/梁用預浸料SparPreg非高壓釜工藝/
Semi-preg SPRINT/SparPreg out-of-autoclave processing
材料選擇
樹脂：多為環(huán)氧樹脂，其他樹脂也可用
纖維：無要求
芯材：大部分，但使用標準PVC泡沫需特別注意高溫
Material options
Resin: epoxy resin is mostly used, other resins can also be used
Fiber: no special requirement
Core: most materials are suitable, but the use of standard PVC foam requires special attention at high temperature
SPRINT/SparPreg非高壓釜工藝：較厚結構（>3mm）中使用預浸料很難在固化過程中將層間或重疊鋪層部分的氣泡排出，為了克服這一困難，預抽真空被引入了鋪層工藝，卻顯著增加了工藝時間。半預浸料SPRINT由兩層干纖維夾一層樹脂膜的夾芯結構組成，材料鋪入模具后，真空泵即可將其中的空氣在樹脂升溫變軟并浸潤纖維前完全抽干，然后再進行固化。梁用預浸料SparPreg是一種改進的預浸料，在真空條件下固化時，可以很容易地將氣泡從粘合的兩層材料間排除。
SPRINT/SparPreg out-of-autoclave processing: When we use the prepreg in thicker structures (>3mm), it is difficult to discharge air bubbles between layers or overlapping layers during the curing process. In order to overcome this difficulty, pre-vacuum is introduced into the layering process, but it significantly increases process time. The semi-preg SPRINT has a sandwich structure which is composed of two-layered dry fibers and one-layer resin film. After the material is placed into the mold, the vacuum pump can completely drain the air before the resin heats up to soften and dip the fibers, and then the curing process can be conducted. The SparPreg is an improved prepreg which can easily remove air bubbles from the bonded two layers of materials when cured under vacuum condition.
典型應用：高性能風電葉片，大型賽艇和游艇，救援飛機
Typical application: high-performance wind turbine blades, large racing boats and yachts, rescue aircrafts
南通新納希新材料有限公司可生產(chǎn)多種復合材料用環(huán)氧樹脂，歡迎廣大新老客戶來電垂詢，我們將竭誠為您服務！
Nantong Synasia New Material Co., Ltd. can produce a variety of epoxy resins for composite materials. Welcome all customers to call us and we will serve you wholeheartedly!
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