Engineered composites offer huge potential across applications from tennis and cycling, to defence and space exploration.
Creating new composites with defined characteristics requires experimentation and research, with new moulding technologies and combinations of materials tested and enhanced until the required performance is achieved.
Gekatex recognise the complexity of composite development – our technical wiping and surface correcting solutions contribute to simpler and more efficient engineering and manufacturing of these materials.
WHAT IS A COMPOSITE MATERIAL?
A simple definition would be something composed of two or more materials, that when combined provide properties superior to those of the original elements.
There are several different types of traditional engineered composites, for example metal alloys such as steel, plywood, or reinforced concrete – but fibre-reinforced polymer (FRP) enables the development and production of lightweight and extremely application-specific composites.
FRP composites consist of:
- Matrix: typically, a resin or plastic that binds the composite and transfers stress.
- Reinforcement: fibres providing stiffness and strength, such as carbon, glass, or aramid.
This technology allows engineers to combine different materials to incrementally optimise performance and create a tailored material with the individual mechanical properties for a specific application.
CHOOSING THE BEST COMPOSITE MATERIAL
Creating the optimal composite involves balancing factors such as:
- Weight and strength requirements
- Budget constraints
- Heat resistance
- Operational lifetime
Each decision impacts the material’s final performance and suitability for its intended use.
THE MATRIX OPTIONS
The matrix, or resin element bonds the composite together, transferring stress and load through the material. There are as many options for the matrix element of a composite as there are performance considerations, for example you could consider thermoset (requiring the addition of a catalyst, or hardener for curing), or thermoplastic (require heat to melt into the required form) resins.
Each of these types contain many different materials and have different benefits in relation to ease-of-use and heat/strength tolerance in application.
SELECTING YOUR REINFORCEMENT
Reinforcement of the matrix will impact how stiff and strong the finished composite is in application. The fibre can be weaved in multiple ways – the direction in which the weave is laid in the composite, will maximise how stiff and strong the composite will be in relation to loading, ensuring the strength of any part is optimised for the application.
Options here include (among others):
- Carbon fibre: excellent stiffness and lightweight, but expensive.
- Glass fibre: flexible and low-cost, but limited in strength.
- Aramid: excellent strength, impact and heat resistance, but difficult to process and soaks up moisture.
MANUFACTURING COMPOSITE MATERIALS
Beyond the combinations of materials available, it is also important to consider the manufacturing process, from wet layup, requiring lots of manual effort in the process to resin transfer moulding – a technique that allows production on a larger commercial scale.
COMPOSITE COMPLEXITY
In summary, there are nearly unlimited combinations of materials available to create a composite part optimised to have the best properties for any application. Budget constraints, specific production needs and other factors can also play a role in determining the different composite elements.
CONSUMABLES FOR COMPOSITE ENGINEERING
Creating and manufacturing new composites often requires new tools, techniques and consumables for efficient production. We will work with you to identify the best technical wiping products and processes for your needs.
Gekatex has previously developed solutions for various composite manufacturing challenges. For example, our Nanotex 320 microfibre wipe for abrasive composites is highly resistant, with no linting – to minimise any potential for contamination.
Our technical wipes attain the highest standards and we operate in critical sectors, such as aerospace, with products that are PRI QPL qualified to AMS 3819D – the Aerospace quality standard.
Acusat presaturated wipes are a quick and simple way to apply releasing agent, or remove oven burnt tape from moulds and ensure the composite surface is perfectly degreased and optimised for bonding/painting.
Get in touch with us and speak to one of our team and find out more about how we can help you: https://gekatex.com/contact-us/
Download a catalogue here: https://gekatex.com/catalogues/