1ENG 4793: Composite Materials and Processes1Filament Windingver 1ENG 4793: Composite Materials and Processes2ENG 4793: Composite Materials and Processes3GT’s machineENG 4793: Composite Materials and Processes4Filament winding machinesENG 4793: Composite Materials and Processes5Creel tensionersENG 4793: Composite Materials and Processes6Integral head resin wet-out bath2ENG 4793: Composite Materials and Processes7Simulated, tapered box beam wound on six-axiscomputer-controlled filament winder. Actual machinemotion indicated by arrowsENG 4793: Composite Materials and Processes8Wet winding box-like structuresENG 4793: Composite Materials and Processes9Layout of a computer-controlledfilament-winding machineENG 4793: Composite Materials and Processes10Workpiece GeometryENG 4793: Composite Materials and Processes11Spherical pressure vesselsENG 4793: Composite Materials and Processes12Gas tanks3ENG 4793: Composite Materials and Processes13Aerospace, Hydrospace, and Military Applications• Rocket motor cases• Rocket motor insulators• Solid propellent motor liners• Nose cones for space fairings• Rocket nose cones• Rocket nozzle liners• Jato motor• APU turbine cases• High-pressure bottles (gas or liquid)• Vacuum cylinders• Torpedo launching tubes• Rocket launcher tubes• Flame thrower tubes• Missile landing spikes• Deep space satellite structures• Radomes• Igniter baskets• Wing dip tanks• Helicopter rotor blades• Thermistors• Liquid rocket thrust chamber• rocket exit cones• Chemical rockets• Chemical tanks• Sounding rocket tubes• Tactical bombardment rockets• Tent poles• Heat shields• Artillery shell shipping grommet• Artillery round-protective cones• Submarine fluid pipes• Submarine tanks and containers• Submarine ventilation pipes• Submarine hulls• Underwater buoys• Cryogenic vessels• Electronic packages• Submarine fairwaters• Sonar domes• Engine cowlingsENG 4793: Composite Materials and Processes14Aerospace partsF-16Patriot missileSoviet missileENG 4793: Composite Materials and Processes15Commercial Applications• High-voltage switchgears• Electrical containers• Decorative buildingssupports•Valves• Boat masts• Lamp poles• Race track railing• Drive shafts• Air brake cylinder• Heating ducts• Pontoons• Irrigation pipes• Oil well tubes• Ladders• Structural tubing• Electrical conduit• Water heating tanks• Highway stanchions• Printed circuit forms• Circuit breaker housing• High-voltage insulators• Antenna/dishes• Motor housingENG 4793: Composite Materials and Processes16Sporting goodsENG 4793: Composite Materials and Processes17Glass epoxy filament-wound 9-foot-diameter by 55-foot-long assembled railway tank carENG 4793: Composite Materials and Processes18Large tanks4ENG 4793: Composite Materials and Processes19Pipe machine and cure ovenENG 4793: Composite Materials and Processes20Light poleENG 4793: Composite Materials and Processes21Typical Tools & Geometry ProducedENG 4793: Composite Materials and Processes22Large self-driven mandrelENG 4793: Composite Materials and Processes23Delta IV Rocket Faring MandrelENG 4793: Composite Materials and Processes24Framework for Plaster Mandrel5ENG 4793: Composite Materials and Processes25Process Needs• Wet Wind– Low viscosity– Long pot life– Resin should gel– Toxicity• Advantages --cheap, one step, nocompaction• Disadvantages --poor resin control,mixing at plant, QCneeded at plant•Prepreg– High viscosity– Latent curatives• Advantages -- nomixing or QC atplant, potential forhigh speedautomatedprocessing• Disadvantages --more costly,compaction neededENG 4793: Composite Materials and Processes26Thermoset Resins•Plus– small molecules react toform larger ones after partwinding--easy processing– tight crosslinking providesstrong, chemically hard, andthermally resistant glass– very easy to modify byblending, mixing, tweaking,and thumping– old, well known technology• Minus– brittle– cure takes time and energy– may crack under thermalcycling– type of polymerization maycause volatiles which hurtperformanceENG 4793: Composite Materials and Processes27Thermoplastic resins•Plus– molecule in fully reacted--only heat and pressureneeded to fuse– remeltable--flows andheals defects– possibility for fullyautomated, rapidmanufacturing• Minus– new emergingtechnology for winding– creeps or flows understress and heat– no wet wind--onlyPREPREG formENG 4793: Composite Materials and Processes28Conditions for Slipping or BridgingENG 4793: Composite Materials and Processes29Winding pins for low angle windingENG 4793: Composite Materials and Processes30Special Filament Winding Methods6ENG 4793: Composite Materials and Processes31Continuous curing ovenENG 4793: Composite Materials and Processes32Multiple spindle machineENG 4793: Composite Materials and Processes33Methods of material fabrication and respectivespecimens and test methodsENG 4793: Composite Materials and Processes34Fabrication Method CostsENG 4793: Composite Materials and Processes35Filament Winding Evaluation• Investment– High Capital equipment– Modest tooling– Consistent parts• Materials– Tailored for filament winding– Variety growing– New for thermoplastics– Multiple tows needed foreconomics• Processing–Fast– Low labor (automated)– Hazards remote (sometimes)• Quality– Only inside surfacesmooth– Voids likely withoutautoclave– Properties can be high• Products– Low to high volume– Small to large areas– Simple contours (avoidundercuts)– Low cost possibleENG 4793: Composite Materials and