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ENG 4793: Composite Materials and Processes 1 ENG 4793: Composite Materials and Processes 2
ENG 4793: Composite Materials and Processes 3 ENG 4793: Composite Materials and Processes 4
ENG 4793: Composite Materials and Processes 5 ENG 4793: Composite Materials and Processes 6
1
Typical products ■Lightweight
• Front and rear end automobile panels ■Durable
■Aerodynamic styling
• Hoods
• Roofs
• Scoops
• Fenders
• Spoilers
• Air deflectors
• Lift gates >100 SMC parts
• Battery trays 450 lb/truck
114 million lb, 1996
ENG 4793: Composite Materials and Processes 7 ENG 4793: Composite Materials and Processes 8
• Advantages:
– Short cycle time (typically 1-6 minutes)
– High volume production
– Class A (high quality) surfaces
• Disadvantages:
– High initial capital investment
– Labor intensive
– Secondary operations are sometimes
required
ENG 4793: Composite Materials and Processes 9 ENG 4793: Composite Materials and Processes 10
2
ENG 4793: Composite Materials and Processes 13 ENG 4793: Composite Materials and Processes 14
ENG 4793: Composite Materials and Processes 15 ENG 4793: Composite Materials and Processes 16
ENG 4793: Composite Materials and Processes 17 ENG 4793: Composite Materials and Processes 18
3
Polyester
Epoxy
• Polyesters can be thermosets or
thermoplastics.
• Do not emit gases during cure
– Thermoset polyesters, such as those used in
compression molding, are formed from linear, • Compared to polyesters:
unsaturated, thermoplastic polyesters which are
– Higher mechanical properties
crosslinked during a cure reaction.
– Longer cycle times
• Special features of polyester resins:
– Does not emit gases (byproducts) during cure – Less desirable surface appearance
– Most common
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• Phenolic
• Urea
• Melamine
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4
Curing Time vs. Mold Temperature for
Manufacturing Factors SMC sheets
Viscosity variation of an SMC before and during Flow of various layers of an SMC charge during
the compression molding operation compression molding
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ENG 4793: Composite Materials and Processes 29 ENG 4793: Composite Materials and Processes 30
5
Effect of cure time on the development of flexural strength
Various defects in a compression-molded
in a compression molded SMC-R laminate SMC part
ENG 4793: Composite Materials and Processes 31 ENG 4793: Composite Materials and Processes 32