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1ENG 4793: Composite Materials and Processes1Toolingver 1ENG 4793: Composite Materials and Processes2Tool Design Options•Cast•Lay-up• Machined• Sprayed-cast• Electro-formedENG 4793: Composite Materials and Processes3MoldsENG 4793: Composite Materials and Processes4MoldENG 4793: Composite Materials and Processes5Mold MachiningENG 4793: Composite Materials and Processes6Tool Considerations• Physicals (pressure, temperature, time,operators)• Economics (cost, quality, productionrate, useful service life)• Part Design (configuration, material,tolerance, size)• Process (filament winding, lay-up,compression molding, etc.)2ENG 4793: Composite Materials and Processes7Cast Composite Tool Fabrication (closed moldfor RTM)1. Create Master Pattern(a multi-step process)2. Define Parting Plane3. Fabricate Parting Plate4. Set-up Pattern andParting Plate5. Fabricate ContainmentBox6. Apply PVA Release7. Apply Surface Coat8. Cast Mold Half9. Invert and RemoveParting Plate10. Apply PVA Release11. Apply Surface Coat12. Cast Mold Half13. Separate Mold Halves14. Remove MasterPattern15. Release and SeasonMoldENG 4793: Composite Materials and Processes8RTM ProcessENG 4793: Composite Materials and Processes9Master Pattern Options• Solids Model• Plaster / Plastic Faced Plaster (PFP)• Polymer Styling Compounds• Tooling Boards• Castable Polymers• Monolithic Graphite•WoodENG 4793: Composite Materials and Processes10Plaster / Plastic Faced Plaster (PFP)ENG 4793: Composite Materials and Processes11Master Pattern Considerations• Physicals (durability, impact resistance,CTE mismatch)• Economics (cost - material, labor)• Part Design (detail, tolerance, size)• Process (machinability, hand work)ENG 4793: Composite Materials and Processes12Relative Tooling CostsType Cost Index*Epoxy/Gypsum Prototype Temporary Tools 0.3Low Mass Laminated Tools - Room TemperaturePolyester, Epoxy3-5High Mass Laminated Tools - TemperatureControlled Polyester, Epoxy5-8Mass Cast Tools - Temperature Controlled Acrylic,Low Profile Polyester, Epoxy5-8Net Cast Aluminum 6-9Electroformed Nickel Steel 12-15Machined Steel 20-50* Open Mold = 1.0Wiseman, D.H., "Method of Mast Casting Molds for RTM", Paper 3-C, 50thAnnual Conference, Composites Institute, SPI, February, 19953ENG 4793: Composite Materials and Processes13Thermal PropertiesMaterial CTE k Max T Cv(ppm/°F) (BTU/in/hr/ft2/°F) (°F) (BTU/ft3/°F)Graphite Epoxy 2-5 100 250-300 20Glass Epoxy 4-6 5 250-300 25Mass Cast Acrylic (Alfilled)13 35 250-300Cast Ceramic 0.5-3 5 2000 30Cast Aluminum 13 1300 600-750 40Nickel 7 450 1000+ 60Steel 6 450 900+ 60ENG 4793: Composite Materials and Processes14Mechanical PropertiesMaterial Comp. Strength(ksi)Graphite Epoxy 40Glass EpoxyMass Cast Acrylic (Al filled)Cast Ceramic 10Cast Aluminum 50Nickel 150Steel 150-300 (hardened)ENG 4793: Composite Materials and Processes15Tooling ComparisonMaterial: Gr/Ep Mass Cast Al Al Spray Ni/Comp SteelFeature Poly/MetalPattern - - + - - +Lead Time + + - -Finish + + + +Tolerance + + +Lifetime - - - - + +Cost + + + + -CTE + - - + +Strength + +Weight + + + + - -Service Temp. - - - - + +ENG 4793: Composite Materials and


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