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SHORT NOTES OF FRP

Fiber Reinforced Plastics Jai SiyaRam Er. Abhishek Singh

2023
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Sandwich Construction Molding Process :

Sandwich construction molding is a process used to

create composite structures consisting of a core
material sandwiched between two face sheets. This
technique is widely used in industries such as
aerospace, automotive, marine, and construction,
where lightweight and high-strength structures are
desired. Here's an overview of the sandwich
construction molding process:

1. Core Material Selection: The first step is to select

the core material for the sandwich structure.
Common core materials include foam,
honeycomb, balsa wood, and syntactic foams.
The choice of core material depends on factors
such as strength requirements, weight
considerations, and specific application needs.
2. Preparation of Face Sheets: Face sheets are the
outer layers of the sandwich structure and
provide structural integrity and protection. The
face sheets are typically made of fiber-reinforced
composite materials such as fiberglass, carbon
 fiber, or aramid fiber. The face sheets are usually
pre-impregnated with resin (prepreg) to ensure
proper resin-to-fiber ratio and optimal
mechanical properties.
3. Assembly of the Sandwich Structure: The
sandwich structure is assembled by placing the
core material between the two face sheets. The
face sheets are carefully aligned and positioned
on either side of the core material to ensure
proper contact and uniform distribution of
forces during the molding process.
4. Molding Process:

a. Vacuum Bagging: In vacuum bagging, the

assembled sandwich structure is placed on a
mold surface. A vacuum bag is then tightly
sealed around the structure, and a vacuum is
applied to remove air and compress the layers
together. The vacuum bagging process ensures
proper consolidation and removes excess resin
during curing.

b. Resin Infusion: Alternatively, the sandwich

structure can be manufactured using resin
infusion techniques. In this method, the
 assembled structure is placed in a mold, and a
vacuum is applied to the mold cavity. Resin is
then introduced into the mold under vacuum,
allowing it to flow and impregnate the fiber
layers and core material.

c. Compression Molding: Compression molding

is another technique used for sandwich
construction. In this process, the assembled
structure is placed in a heated mold, and
pressure is applied to compress the layers
together. Heat and pressure facilitate the curing
of the resin, resulting in a consolidated sandwich
structure.
5. Curing: After the molding process, the sandwich
structure is cured to ensure the resin hardens
and achieves its desired mechanical properties.
The curing process typically involves applying
heat and pressure, or using a controlled curing
cycle, depending on the resin system being
used.
6. Trimming and Finishing: Once the sandwich
structure has cured, it is removed from the mold
and trimmed to the desired size and shape.
 Additional finishing processes, such as sanding,
painting, or coating, may be carried out to
achieve the desired aesthetics and surface
properties.

Sandwich construction molding offers several

advantages, including high strength-to-weight ratio,
good stiffness, excellent impact resistance, and
thermal insulation. The process allows for the
creation of complex shapes and can be tailored to
meet specific performance requirements. However, it
requires careful design and manufacturing
considerations to ensure proper adhesion,
alignment, and consolidation of the layers for
optimal structural performance.

SURFACING TISSUE :-
Surfacing tissue, also known as surface veil or finishing veil,
plays a crucial role in fiber-reinforced polymer (FRP)
composites. It is a thin, lightweight non-woven material
that is applied to the surface of the composite laminate
during the manufacturing process. The surfacing tissue
serves several important functions:

1. Surface Protection: One of the primary roles of

surfacing tissue is to protect the underlying composite
laminate from environmental factors such as UV
radiation, moisture, chemicals, and abrasion. It acts as
a barrier, preventing these elements from degrading
the composite's structural integrity and aesthetics
over time.
2. Improved Surface Finish: Surfacing tissue helps to
achieve a smoother and more uniform surface finish
on the composite laminate. It covers the reinforcing
fibers and resin-rich areas, minimizing the appearance
of fiber print-through (the visible outline of the
underlying fibers). This results in an enhanced
cosmetic appearance of the composite part, making it
more visually appealing.
3. Enhanced Durability: By providing an additional layer
of reinforcement, surfacing tissue increases the overall
durability and impact resistance of the composite
laminate. It helps to distribute and absorb external
forces, reducing the risk of surface damage, cracking,
or delamination.
4. Reduced Water Ingression: Surfacing tissue acts as a
diffusion barrier, hindering the ingress of water and
other liquids into the composite structure. This barrier
 function helps to prevent moisture absorption, which
can lead to degradation, dimensional changes, and
loss of mechanical properties over time.
5. Improved Chemical Resistance: The surfacing tissue
can provide an additional layer of chemical resistance
to the composite laminate. It acts as a shield against
corrosive substances, acids, solvents, and other
chemicals that could potentially attack the underlying
composite matrix or fibers.
6. Bonding Enhancement: When used in conjunction
with adhesives or surface coatings, surfacing tissue
can improve the bonding strength and adhesion
between the composite laminate and subsequent
layers. It provides a compatible surface for the
application of paints, coatings, or secondary
laminations.
7. Easier Surface Preparation: Surfacing tissue can
simplify the surface preparation process before
secondary operations such as painting or bonding. It
helps to create a uniform surface texture, making it
easier to achieve good adhesion and finish quality.

It's important to note that the selection of the appropriate

surfacing tissue depends on specific requirements, such as
the intended application, resin system, environmental
conditions, and desired surface finish. The choice of
surfacing tissue can vary in terms of weight, thickness,
fiber type (e.g., fiberglass or synthetic), and compatibility
with the resin system being used.

Overall, surfacing tissue significantly contributes to the

performance, durability, aesthetics, and protection of FRP
composites, making it an essential component in many
composite applications, including automotive parts,
marine vessels, wind turbine blades, and architectural
structures.