分析六种最常见复合材料成型加工工艺的优缺点

分析六种最常见复合材料成型加工工艺的优缺点

目录

1.序言.................................................................................................1

2.Prepreg/Autoclave（预浸料/高压釜）...................................................................3

3.Results：航空级......................................................................................4

3.1.等级：中级技能.................................................................................4

3.2.ResinTransferMolding（树月台传递模塑）.........................................................6

4.Results：优秀的装饰品................................................................................6

4.1.技能等级:高技能...............................................................................6

4.1.1.ResinInfusion（树脂灌注）.................................................................8

5.Results：消费品等级..................................................................................8

5.1.技能等级：中级技能............................................................................8

5.1.1.Prepreg/OvenCure（预浸料/烘箱固化）....................................................10

6.Results：消费品级...................................................................................10

6.1.技能等级：中级技能............................................................................10

6.1.1.PressMolding（模压成型）................................................................12

7.Results：高度可预测的结果..........................................................................12

7.1.技能水平：一般技能...........................................................................12

7.1.1.WetLayup（湿铺工艺）..........................14

8.Results：低等级.....................................................................................14

8.1.技能水平：低技能..............................................................................14

1.序言

在本文中将从Process、Results>Materials>Tooling、OperationCost^Equipment等6个方面

对复合材料常见加工工艺Prepreg/Autoclave（预浸料/高压釜）、ResinTransferMolding（RTM,

树脂传递模塑）、ResinInfusion（树脂灌注）、Prepreg/OvenCure（预浸料/烘箱固化）、Press

Molding（模压成型）和WetLayup（湿铺工艺）进行定性定量对比评价。

在6个方面进行定量评价时，以满分10分为最高分、0分为最低分进行考量；其中Process过

程考量主要涉及Cleanliness（清洁度）、Volatilerelease（挥发剂释放）等6个方面;Results考量

涉及Repeatability（可重复性）、Voidcontent（孔隙量）等10个方面;Materials考量涉及Cost

ofmaterials（材料成本）等4个方面;Tooling考量涉及Toolingcost（工具成本）等3个方面；

OperationCostLaborintensity（劳动强度）等3个方面；Equipment考量涉及Equipment

第1页共15页

expense（设备费用）等3个方面。

图1和表1中汇总了6种常见复合材料加工工艺定量考核的指标，下面将针对这6种常见工

艺进行一一评述。

ComparisonofMethods

PP/AUTORIRTMPP/OVENWetPRESS

Process

Results

Materials

Tooling碳纤维及其复白材料技方

图1常见6种复合材料定量评价

表1常见6种复合材料具体考量指标

第2页共15页

PP/ACRTMRIPP/OCWLPM

ProcessProcessScore(higherisbetter)8.74.86.78.72.36.7

CleanlinessMessy0<—>10Clean975919

Difficulty/SkillLevelDifficult0<—>10Easy423427

SeconcaryOps,trimmingetc.NcOps0<—>10MoreOps1011010103

VolatilereleaseOpenAir0<—>10None1010101003

ControlledcurecyclesNone0<—>10Controlled105510010

ControlledresincontentNone0<—>10Controlled947918

ResultsResultsScore(higherisbetter)9.27.46.78.12.08.0

CompactionNone0<—>10Best10556210

ComplexityofpartNone0<—>10Best895648

RepeatabilityNone0<—>10Best888729

VoidContentHigh0<—>10Low997719

FiberOrientationControlNone0<—>10Best10681015

ResinRichnessHigh0<—>10Low925909

RepeatableMechanicalPropertiesLow0<—>10High977919

ControlledWeightLow0<一>10High108910210

PorosityHigh0<—>10Low9108729

CoreCo-CuringBad0<—>10Good101051052

MateriakMaterialsScore(higherisbetter)1.66.26.41.68.63.0

ConsumablecostHigh0<—>10Low3923710

MinimumOrderQuantityofmaterialsHigh0<—>10Low166191

RoomtempcureresinsystemsLow0<—>10High05100100

CostofmatenalsHigh0<一>10Low368393

ShelflifeofmaterialsLow0<—>10High156181

ToolinqToolingScore(higherisbetter)3.35.36.73.36.05.0

AllsurfacesaretooledOne0<—>10Multiple5105527

ToolingCostHigh0<—>10Low315371

CTEissuesHigh0<—>10Low2510297

OperationCostOperationScore(higherisbetter)2.03.36.73.06.04.3

FacilityCostHigh0<—>10Low22648A

FacilityDedicationHigh0<—>10Low169292

LaborIntensityHigh0<—>10Low325317

EquipmentEquipmentScore(higherisbetter)0.34.78.33.79.70.7

EquipmentExpenseHigh0<—>10Low148392

DedicateduniqueequipmentHigh0<—>10Low0078100

PartlimitedtoequipmentsizeNone0<—>10High010100100

[AverageScore(higherisbetter)

PP/AC=Prepreg/Autoclave,RTM=ResinTransferMolding,RI«ResinInfusion,PP/OC=Prepreg/OvenCure,WL=WetLayup,PM-PressMolding

2.Prepreg/Autoclave(预浸料/高压釜)

第3页共15页

Prepreg/Autoclave

Process

EquipmentResults

Operation

Materials

Cost

碳纤维及其复台材料技才

Too|jng

3.Results：航空级

3.1.等级：中级技能

在质量方面，基于预浸料的结构件在高压釜中固化，使其具有特定的优势。该过程可以高度控

制，从而产生优异的结果。但主要挑战包括昂贵的材料、工具、运营成本和设备。

第4页共15页

PREPREG/AUTOCLAVE

ProcessProcessScore(higherisbetter)8.7

CleanlinessMessy0<—>10Clean9

Difficulty/SkillLevelDifficult0<—>10Easy4

SecondaryOps,trimmingetc.NoOps0<—>10MoreOps10

VolatilereleaseOpenAir0<一>10None10

ControlledcurecyclesNone0<—>10Controlled10

ControlledresincontentNone0<一>10Controlled9

ResultsResultsScore(higherisbetter)9.2

CompactionNone0<一>10Best10

ComplexityofpartNone0<—>10Best8

RepeatabilityNone0<一>10Best8

VoidContentHigh0<—>10Low9

FiberOrientationControlNone0<—>10Best10

ResinRichnessHigh0<一>10Low9

RepeatableMechanicalPropertiesLow0<—>10High9

ControlledWeightLow0<一>10High10

PorosityHigh0<一>10Low9

CoreCo-CuringBad0<一>10Good10

MaterialsMaterialsScore(higherisbetter)1.6

ConsumablecostHigh0<一>10Low3

MinimumOrderQuantityofmaterialsHigh0<■一>10Low1

RoomtempcureresinsystemsLow0<—>10High0

CostofmaterialsHigh0<一>10Low3

ShelflifeofmaterialsLow0<—>10High1

ToolingToolingScore(higherisbetter)3.3

AllsurfacesaretooledOne0<—>10Multiple5

ToolingCostHigh0<一>10Low3

CTEissuesHigh0<一>10Low2

OperationCostOperationScore(higherisbetter)2.0

FacilityCostHigh0<一>10Low2

FacilityDedicationHigh0<一>10Low1

LaborIntensityHigh0<—>10Low3

EquipmentEquipmentScore(higherisbetter)0.3

EquipmentExpenseHigh0<—>10Low1

DedicateduniqueequipmentHigh0<->IQ

None拓-%krKx"

Partlimitedtoequipmentsize

第5页共15页

3.2.ResinTransferMolding（树脂传递模塑）

ResinTransferMolding

Process

10

Tooling、二公顽纤维及其复合材科技才

4.Results：优秀的装饰品

4.1.技能等级：高技能

使用树脂传递模塑工艺制造的部件可以产生美丽的外观。但该过程确实需要高水平的技能，并

且所有表面都必须经过加T处理，优势之一是材料成本较低°

第6页共15页

RESINTRANSFERMOLDING

ProcessProcessScore(higherisbetter)4.8

CleanlinessMessy0<—>10Clean7

Difficulty/SkillLevelDifficult0<—>10Easy2

SecondaryOps,trimmingetc.NoOps0<—>10MoreOps1

VolatilereleaseOpenAir0<—>10None10

ControlledcurecyclesNone0<一>10Controlled5

ControlledresincontentNone0<—>10Controlled4

ResultsResultsScore(higherisbetter)7.4

CompactionNone0<—>10Best5

ComplexityofpartNone0<—>10Best9

RepeatabilityNone0<-->10Best8

VoidContentHigh0<—>10Low9

FiberOrientationControlNone0<—>10Best6

ResinRichnessHigh0<—>10Low2

RepeatableMechanicalPropertiesLow0<--->10High7

ControlledWeightLow0<■一>10High8

PorosityHigh0<—>10Low10

CoreCo-CuringBad0<—>10Good10

MaterialsMaterialsScore(higherisbetter)6.2

ConsumablecostHigh0<一>10Low9

MinimumOrderQuantityofmaterialsHigh0<—>10Low6

RoomtempcureresinsystemsLow0<--->10High5

CostofmaterialsHigh0<一>10Low6

ShelflifeofmaterialsLow0<—>10High5

ToolingToolingScore(higherisbetter)5.3

AllsurfacesaretooledOne0<—>10Multiple10

ToolingCostHigh0<—>10Low1

CTEissuesHigh0<—>10Low5

OperationCostOperationScore(higherisbetter)3.3

FacilityCostHigh0<—>10Low2

FacilityDedicationHigh0<—>10Low6

LaborIntensityHigh0<—>10Low2

EquipmentEquipmentScore(higherisbetter)4.7

EquipmentExpenseHigh0<—>10Low4

Dedicateduniqueequipment----------High0餐监”f

PartlimitedtoequipmentsizeNone0展

第7页共15页

4.1.1.ResinInfusion（树脂灌注）

ResinInfusion

Process

10

EquipmentResults

Operation

Materials

Cost

Tooling、七破纤经及其夏白，田抖宓i；

5.Results：消费品等级

5.1.技能等级：中级技能

使用树脂灌注制造部件将产生消费品级结果。如果有预算，这是一个很好的过程，因为入门成

木不高.树脂灌注不需要特殊的设施C

第8页共15页

RESININFUSION

ProcessProcessScore(higherisbetter)6.7

CleanlinessMessy0<—>10Clean5

Difficulty/SkillLevelDifficult0<—>10Easy3

SecondaryOps,trimmingetc.NoOps0<-->10MoreOps10

VolatilereleaseOpenAir0<—>10None10

ControlledcurecyclesNone0<—>10Controlled5

ControlledresincontentNone0<—>10Controlled7

ResultsResultsScore(higherisbetter)6.7

CompactionNone0<—>10Best5

ComplexityofpartNone0<—>10Best5

RepeatabilityNone0<—>10Best8

VoidContentHigh0<—>10Low7

FiberOrientationControlNone0<—>10Best8

ResinRichnessHigh0<—>10Low5

RepeatableMechanicalPropertiesLow0<—>10High7

ControlledWeightLow0<—>10High9

PorosityHigh0<—>10Low8

CoreCo-CuringBad0<—>10Good5

MaterialsMaterialsScore(higherisbetter)6.4

ConsumablecostHigh0<-->10Low2

MinimumOrderQuantityofmaterialsHigh0<—>10Low6

RoomtempcureresinsystemsLow0<—>10High10

CostofmaterialsHigh0<—>10Low8

ShelflifeofmaterialsLow0<--->10High6

ToolingToolingScore(higherisbetter)6.7

AllsurfacesaretooledOne0<—>10Multiple5

ToolingCostHigh0<—>10Low5

CTEissuesHigh0<—>10Low10

OperationCostOperationScore(higherisbetter)6.7

FacilityCostHigh0<—>10Low6

FacilityDedicationHigh0<—>10Low9

LaborIntensityHigh0<-->10Low5

EquipmentEquipmentScore(higherisbetter)8.3

EquipmentExpenseHigh0<—>10Low8

DedicateduniqueequipmentHigh0<—>10Lowa7•L-

曲电不

PartlimitedtoequipmentsizeNoneOvNC醺今阴药以具聂可河;

第9页共15页

5.1.1.Prepreg/OvenCure（预浸料/烘箱固化）

Prepreg/OvenCure

EquipmentResults

Operation

Materials

Cost

Tooling、化锻纤经及其叟白，同料宓i：

6.Results：消费品级

6.1.技能等级：中级技能

构建预浸材料结构件并在烘箱中固化，将为具有正确技术技能和设施的人员提供消费品级的结

果，其挑战主要包括昂贵的材料和大量的劳动力，但设备比高压釜便宜C

第10页共15页

PREPREG/OVENCURE

ProcessProcessScore(higherisbetter)8.7

CleanlinessMessy0<—>10Clean9

Difficulty/SkillLevelDifficult0<—>10Easy4

SecondaryOps,trimmingetc.NoOps0<—>10MoreOps10

VolatilereleaseOpenAir0<—>10None10

ControlledcurecyclesNone0<—>10Controlled10

ControlledresincontentNone0<—>10Controlled9

ResultsResultsScore(higherisbetter)8.1

CompactionNone0<—>10Best6

ComplexityofpartNone0<—>10Best6

RepeatabilityNone0<—>10Best7

VoidContentHigh0<—>10Low7

FiberOrientationControlNone0<—>10Best10

ResinRichnessHigh0<—>10Low9

RepeatableMechanicalPropertiesLow0<一>10High9

ControlledWeightLow0<—>10High10

PorosityHigh0<—>10Low7

CoreCo-CuringBad0<—>10Good10

|MaterialsMaterialsScore(higherisbetter)1.6

ConsumablecostHigh0<—>10Low3

MinimumOrderQuantityofmaterialsHigh0<-->10Low1

RoomtempcureresinsystemsLov-/0<—>10Hiah0

CostofmaterialsHigh0<—>10Lov?3

ShelflifeofmaterialsLow0<—>10High1

ToolingToolingScore(higherisbetter)3.3

AllsurfacesaretooledOne0<—>10Multipl5

ToolingCostHigh0<--->10Low3

CTEissuesHigh0<—>10Low2

OperationCostOperationScore(higherisbetter)3.0

FacilityCostHigh0<—>10Low4

FacilityDedicationHigh0<—>10Lov/2

LaborIntensityHigh0<—>10Low3

EquipmentEquipmentScore(higherisbetter)3.7

EquipmentExpenseHigh0<—>10Low3

——8」

DedicateduniqueequipmentHigh0<—>10Low

PartlimitedtoequfjnieritsizeNone0<-工」嫉等需及其复可正科技不

第11页共15页

6.1.1.PressMolding（模压成型）

PressMolding

Process

w

EquipmentResults

Operation

Materials

Cost

Tooling■「碳纤维及其夏餐材料宓i；

7.Results：高度可预测的结果

7.1.技能水平：一般技能

使用模压成型制造复合材料结构件是一个相对简单的过程，具有一般技能的人可以进行。它将

需要专用设施和昂贵的设备C除了高消耗外.昂贵的T具和材料也增加了成本C但是可以获得可预

测的结果，这对于大批量生产来说是理想的选择。

第12页共15页

PRESSMOLDING

ProcessProcessScore(higherisbetter)6.7

CleanlinessMessy0<—>10Clean9

Difficulty/SkillLevelDifficult0<—>10Easy7

SecondaryOps，trimmingetc.NoOps0<—>10MoreOps3

VolatilereleaseOpenAir0<—>10None3

ControlledcurecyclesNone0<—>10Controlled10

ControlledresincontentNone0<-->10Controlled8

ResultsResultsScore(higherisbetter)8.0

CompactionNone0<—>10Best10

ComplexityofpartNone0<—>10Best8

RepeatabilityNone0<—>10Best9

VoidContentHigh0<—>10Low9

FiberOrientationControlNone0<—>10Best5

ResinRichnessHigh0<—>10Low9

RepeatableMechanicalPropertiesLow0<--->10High9

ControlledWeightLow0<—>10High10

PorosityHigh0<一>10Low9

CoreCo-CuringBad0<—>10Good2

MaterialsMaterialsScore(higherisbetter)3.0

ConsumablecostHigh0<—>10Low10

MinimumOrderQuantityofmaterialsHigh0<—>10Low1

RoomtempcureresinsystemsLow0<—>10High0

CostofmaterialsHigh0<—>10Low3

ShelflifeofmaterialsLow0<—>10High1

ToolingToolingScore(higherisbetter)5.0

AllsurfacesaretooledOne0<-->10Multiple7

ToolingCostHigh0<—>10Low1

CTEissuesHigh0<—>10Low7

OperationCostOperationScore(higherisbetter)4.3

FacilityCostHigh0<—>10Low4

FacilityDedicationHigh0<—>10Low2

LaborIntensityHigh0<—>10Low7

EquipmentEquipmentScore(higherisbetter)0.7

EquipmentExpenseHigh0<—>10Low2

DedicateduniqueequipmentHigh0<—>10Low0

PartlimitedtoequipmentsizeNone0<---J滋疑酋应其复宣「材料技术

第13页共15页

7.1.1.WetLayup（湿铺工艺）

WetLayup

Process

10

Results

Materials

Tooling碳纤维及其复合材料及方

8.Results：低等级

8.1.技能水平：低技能

使用湿铺工艺制造复合材料结构件不会产生很好的效果，但它对初学者有好处，而且