Project Name: DESIGN AND MANUFACTURING OF A VACUUM INFUSION SYSTEM FOR MANUFACTURING ADVANCED COMPOSITES (supervised by Dr.

Merve Erdal) Purpose of the Project: To develop a vacuum infusion system that will be used to produce advanced composite components for research and education at the Composites Lab in METU Mechanical Engineering Department Description: The Vacuum Infusion Process (VIP) is a technique that uses vacuum pressure to drive liquid thermosetting resin into a dry fabric laminate to produce relatively large, advanced composites. Materials such as fiberglass or carbon fiber fabrics are laid dry onto the one-sided mold. The laminate of the fabric layers may then be covered with layers of aid material (that will help infusion). The mold is at last covered with a vacuum bag and vacuum is applied before any resin is introduced. Once a complete vacuum is achieved, resin is literally sucked into the laminate via carefully placed tubing. This process is aided by an assortment of supplies and materials.

(figure from http://bodykits.files.wordpress.com/2008/01/vacuum-infusion.jpg) Project Requirements: 1. Appropriate processing materials, equipment and aids will be researched and purchased (some funds are available) 2. The developed system will be used to manufacture a continuous fiber reinforced thin composite product that has a 3-D feature (e.g. thin plate with some curvature like a car hood or boat hull) 3. A composite part with its planar size (when projected on a plane) no less than 1 m2 will be produced 4. An appropriate tool (mold) will be designed and produced on which the dry fabrics will be laid for the infusion production of the composite 5. The optimum infusion strategy will determined so as to yield a successful process, i.e. the optimum placement of vacuum tubing, resin inlet(s), in-bag extensions of these tubes, collection and removal of excess resin, etc. 6. Excess resin will be controlled and will not interfere in any way with the success of the process 7. The design and manufacturing experience with all the encountered difficulties, problems and found solutions will be documented in a special report 8. A detailed users manual will be prepared to allow other users to produce composite parts with this system Design Criteria: 1. 2. 3. 4. 5. 6. 7. No dry spots/air pockets in the produced part No creases (wrinkles) in the part; smooth surface No (or minimum) variation in part thickness Excess resin should not be a source of problems in the process No uncontrolled resin leaks vacuum must be fully enforced Resin should be able to cure at room temperature Ease of processing (preparation, infusion and part removal as well as ease of application of the system for another part geometry) 8. Low cost