Deakin University

School of Engineering

Faculty of Science, Engineering and Built Environment

Master of Engineering (Professional)

Advanced Manufacturing Technology (SEM722)

Assignment 1

Name – Mohammed Imran

Student ID – 219068545

Waurn Ponds, August 2019

Literature Review on Composite Processing (Based on Lab Experiments)
Introduction -
A Composite material is a material made up of two or more constituent materials, which has
different characteristics and when combine form characteristics different from both the individual
materials (En.wikipedia.org, 2019). The individual materials remain distinct within finished structures
and differentiates from solid materials and mixtures of other components. In many cases, new materials
are preferred because of its attractive nature. As per one of the researches, Composite materials has
more strength and stiffness when compared with traditional materials (Curious, 2015). Engineers have
many choices during the manufacturing processes to determine what properties of resulting composite
material will be (Composites Lab, 2016).
Few Examples of composite materials are Reinforced concrete, Engineering Bamboo, Glass
tempered reinforced concrete, Parquetry, Ceramic Matrix composite, Plastic coated paper, synthetic
foams etc [4]. Composite materials are acclaimed as “Materials of the future”. So many questions arise
whether composite materials will remain the materials of the future. There are many processes, by
undertaking can manufacture composite materials with different characteristics and strengths[5].
EXPERIEMENTAL DESCRIPTION
This experiment dealt about making a laminate, and 5 different laminates with different characteristics
were considered. Composite experiments of two unidirectional laminates, one Mix laminates which
constituents of two or more components and lastly two 2x2 twill components which is firmly elastic
having more elasticity characteristics. All these laminates are kept in a peel ply board with dimensions
of 150 x 500mm and pump being attached. Group of 4 students and each of the team members working
on different tasks. Simultaneously, Resin was poured down and time for each laminate was recorded.
The Recorded values are described in the table which will be discussed below. As we all know that
Composites are made up on one main material and other background material. The way particles of
reinforcement are arranged in the matrix whether a composite has the same mechanical properties in
same direction or different properties in different directions. This helps in determining the bend and its
directional perspective. The time plays a vital role as more time during the processing makes the
composite material stiff and hard. Less processing time makes it more elastic. Another aspect of the
experiment was to learn how to use Differential Scanning Calorimetry (DSC) for initial heal flow
measurements. Also, conduct a three-point bend test in the Instron. This experiment done in the practical
also focuses on the polymerization and what all factors required for the reaction processing.
Additionally, knowledge on types of polymerization formations were also studied.
Experiment metals used for Analysis -
Different materials were considered for the experiment and was co-joined to form a component
of mixtures. In this experiment 3 different materials are considered as Aluminium, 316 Stainless steel,
and 1040 steel. Aluminium is white silvery metal and is 13th element in the periodic table. It is regarded
as the third most chemical on earth that is abundant after silicon and oxygen. As per a research paper,
10% of the earth’s core is covered with aluminium metal[6]. It falls into non-ferrous metal because of
its radicle properties like corrosion resistant at high pressure and temperatures. On comparing with Iron,
it was found out Aluminium is lighter than iron but stronger than iron and is also highly flexible[7].
Stainless steel is highly resistant to corrosion and contains 10.5% of chromium in it thus giving
special properties in the nature of steel. Stainless steel has many desirable mechanical properties giving
us good performance, huge life structures and is capable of using in construction and other works[8].
Experiment –
Three materials are being tested in this experiment and the information is provided in a given table
below:
For UD[1]
Time(in
Description Sec)
Pour Resin 13
Bag on 10
No Leaks 8
Tool Flipped 12
Tool Wet 24
Flow Stopped (Wet stop) 9

For UD[2]
Time(in
Description Sec)
Pour Resin 18
Bag on 11
No Leaks 10
Tool Flipped 14
Tool Wet 32
Flow Stopped (Wet stop) 6

For Mix (Aluminium, Stainless steel and iron)

Time(in
Description Sec)
Pour Resin 8
Bag on 5
No Leaks 4
Tool Flipped 9
Tool Wet 14
Flow Stopped (Wet stop) 3
For 2x2 Twill
Time(in
Description Sec)
Pour Resin 15
Bag on 18
No Leaks 16
Tool Flipped 8
Tool Wet 22
Flow Stopped (Wet stop) 10

The Calculations were observed, and Heating/cooling values were calculated using Differential
Scanning Calorimetry(DSC).
Cure Kinetics and Rheology Calculations –
To measure the absorbed/ Released energy during heating/cooling, calculating the Cure Kinetics and
Rheology measurements are necessary. This can be found out using the formula below. This is also
known as Arrhenius law which gives
K = A exp(-E/RTp)
Where,
A = Frequency/ pre-exponential factor
-E = Activation energy
R = Universal Gas constant
Tp = Temperature
Calculating for each Laminate, the values of Cure Kinetics can be found out.
The values of Cure kinetics are found out for each material and is depicted below:
Cure
Material Kinetics
UD1 1.06
UD2 2.19
Mix 0.01
2x2 Twill 1 0.89
2x2 Twill 2 0.16

Pre-requisite data for calculation of Cure Kinetics, Temperature maintained kept on fluctuating
depending on the higher ratio of movements. At certain times, heat flow is directly proportional to
Temperature, since as the temperature increases Heat flow increases. At a point Heat flow reaches the
highest proportion. This is called as Maximum temperature. The Temperature Where the heat flow
starts is the Actual temperature. The Residual heat of reaction is the total amount of heat formed
measured in J/g. Based on the graphs plotted, ∆h = 499.8J/g
𝒋
And ∆𝒉𝑹 = 𝟑𝟎𝟖. 𝟓
𝒈
Similarly, Degree of Curing has to be calculated and is done by using the formula
∆𝒉𝒓 ∆𝒉𝒓
∝ = ∆𝒉 − ∆𝒉
= 1- ∆𝒉

= 1- (308.5/499.8) = 0.3827 j/g

The Degree of Cure or it is also known as Conversion% is the amount of crosslinking that has occurred
relative to full potential and is available to thermostat. The speed and extent at which the conversion
percentage occurs is related to heating rate of temperature during the curing of materials.
The viscosity of the materials is often being repeatedly changing depending upon the conditioning of
particles movement during the stage of formations of various materials. The Viscosity of different
materials at different temperatures. So many conditionings are applied in order to restrict the movement
of materials in the positive way and taking it to making a count towards formation of laminates.
Process Optimisation –
Process optimisation is the development of technologies to facilitate cost-effective of all the composite
materials and make sure the production is highly solidified and efficient depending on the condition of
material movements[9]. In this process, by reducing the temperature and adding more resin to make
material stiffer and stronger. Since we are dealing more with Non-Newtonian fluids it is important to
deal with the deformation and flow of matter concerning liquids and plastic flow of solids. Another,
Methodology suggests increasing the flow rate in less time to avoid formation of bubbles which will
make the composite materials as bubbles. Bubbles make the material deformed and uncertain and make
it less strong. Less strong means less stiffness and having low material characteristics which will reduce
the life span of materials which can be degraded. During experiments it was also found out that,
choosing of materials to form into a single composite material matters a lot as material characteristics
have special properties to form into an isolated particulate and the flow rate degrades. Based on another
report, it can be noted that Composite materials often form into unbreakable stuffs which are specifically
formulated for resisting hard stuffs mostly in the construction jobs and other radicle works. Another
research suggests giving more heating time, so particles flow freely and take more time to settle. Thus,
these materials can be formed in different shapes and sizes depending on the requirement.
During the lab sessions, with different materials being manufactured, there is always a way to find out
what combinations forms products of more good quality. At Deakin, it is learned to manufacture such
materials depending on requirements and innovate things which are perspective based.
Quality Control Testing –
After the formation of composite materials, it has to be tested to find out the tenacity, stiff, hardened,
material formation, properties test it whether it is stronger enough to withstand the pressure built on it
and go along the flow rate. Here, temperature plays a vital role in determining the understanding of
composite material. The results below show the flow pattern of each material which was tested and
concluded the strongest of all. Generally, at different engineering sectors quality testing is done to
negate the consequences leading to strength of materials and weaknesses formed at the crucial junctures.

Experimental results –
For the experimental values of UD material, the graphs are plotted which depicts the time and force
behind the criteria. The force is taken on X-axis and time is plotted on Y-axis. Below is the graph
generated during the experimentation
Justification –
As the time progresses the material needs more time to carry out the processing. Generally, for the UD
material it requires more force during its formation into composite materials which indirectly result in
the strength of the products.
For Mix material –
As the composite material is a mixture of aluminium and stainless steel, this has slightly different
phenomena which shows in the below graph.

Justification –
Here, fluctuation of time plays a pivotal role. As the Time progresses, the changes are observed as force
and time is uneven. It is uneven until the material is completely formed out.
Conclusion –
Based on the experimental values and labs conducted, the main aim was to form composite values using
different materials and combining it into 1. Different materials comprising of UD, Mix and 2x2 twill
which will have more elasticity power and strength and is different from all the other aspects and forms.
The experiment was conducted with each student donning one or the other duties like noting down time
for the activities and so on. Coming to the literature review it can be noted that to make materials stiffer
and harder enough, the material needs to be manipulated by increasing the temperature or flow rate.
This will increase the tenacity, strength and hardness which makes material stronger. Another way is to
use less flow rate and increase the time with proper mixing as the flow makes the molecules flow rightly
and avoid formation of bubbles which in terms it relatively depends on the materials combinations.
References –
[1]"Composite material", En.wikipedia.org, 2019. [Online]. Available:
https://en.wikipedia.org/wiki/Composite_material
[2]"Composites Manufacturing Processes", CompositesLab, 2016. [Online]. Available:
http://compositeslab.com/composites-manufacturing-processes
[3]"The science and technology of composite materials", Curious, 2015. [Online]. Available:
https://www.science.org.au/curious/technology-future/composite-materials
[4]J. Spacey, "19 Types of Composite Material", Simplicable, 2018. [Online]. Available:
https://simplicable.com/new/composite-material
[5]F. Abrams and R. Davé, Processing of composites. Munich: Hanser, 2000
[8]"Stainless steel", En.wikipedia.org, 2018. [Online]. Available:
https://en.wikipedia.org/wiki/Stainless_steel
[9]"Process Optimisation - an overview | ScienceDirect Topics", Sciencedirect.com, 2015. [Online].
Available: https://www.sciencedirect.com/topics/engineering/process-optimisation