Composite technologies and restoration of industrial pumps. Modern high technology Composite technologies

I devoted it to the history of composite materials. I continue to spend my free time on this topic and today I want to talk a little about the terms and technologies of prototyping using polymer composites. If you have nothing to do for long winter evenings, then you can always make a snowboard, a motorcycle case, or a smartphone case from carbon fiber fabric. Of course, the process may end up being more expensive than buying a finished product, but it’s interesting to make something with your own hands.

Below the cut is a review of methods for manufacturing products from composite materials. I would be grateful if you add me in the comments so that the result is a more complete post.

A composite material is created from at least two components with a clear boundary between them. There are layered composite materials - for example, plywood. In all other composites, the components can be divided into a matrix, or binder, and reinforcing elements - fillers. Composites are usually divided according to the type of reinforcing filler or matrix material. You can read more about the use of composites in the post History of Composite Materials, and this post focuses on methods for making products from composites.

Hand molding

In the case of making products in single copies, the most common method is hand molding. Gelcoat is applied to the prepared matrix - a material to obtain a good finish on the outer part of the reinforced material, which also allows you to select the color for the product. Then a filler is placed in the matrix - for example, fiberglass - and impregnated with a binder. We remove air bubbles, wait until everything cools down, and finish it with a file - cut it, drill it, and so on.

This method is widely used to create body parts for cars, motorcycles and mopeds. That is, for tuning in cases where it is not limited to sticking a “carbon-look” film.

Sputtering

Spraying does not require cutting glass material, but in return it is necessary to use special equipment. This method is often used to work with large objects, such as boat hulls, vehicles and so on. In the same way as in the case of hand molding, the gelcoat is applied first, then the glass material.

RTM (injection)

The method of injecting polyester resin into a closed mold uses equipment from a matrix and a counter mold - a punch. The glass material is placed between the matrix and the response mold, then a hardener - polyester resin - is poured into the mold under pressure. And, of course, finishing with a file after curing - to taste.

Vacuum infusion

The vacuum infusion method requires a bag in which a vacuum is created using a pump. The bag itself contains reinforcing material, the pores of which, after pumping out the air, are filled with a liquid binder.

An example of a method is for making a skateboard.

Winding

The composite winding method makes it possible to make ultra-light cylinders for compressed gas, for which they use a PET liner pumped up to 2-5 atmospheres, as well as composite pipes used in the oil industry, chemical industry and public utilities. From the name it is easy to understand that fiberglass is wound around a moving or stationary object.

The video shows the process of winding fiberglass onto a cylinder.

Pultrusion

Pultrusion is “broaching”. This method involves a continuous process of pulling the composite material through a pulling machine. The process speed is up to 6 meters per minute. The fibers are passed through a polymer bath, where they are impregnated with a binder, and then pass through a preforming device to obtain the final shape. The material is then heated in the mold to produce the final hardened product.

The process of producing sheet piles using pultrusion.

Direct pressing

Thermoplastic products are manufactured in molds under pressure. For this purpose, high-temperature hydraulic presses with a force from 12 to 100 tons and maximum temperature about 650 degrees. Plastic buckets, for example, are made this way.

Autoclave molding

An autoclave is necessary for carrying out processes under heat and pressure above atmospheric pressure in order to speed up the reaction and increase the yield of the product. Composite materials are placed inside the autoclave on special forms.

Composite Products

Composite materials are widely used in aircraft manufacturing. For example, Solar Impulse is built from them.

Automotive industry

Prostheses and orthoses.

If you have any additions, be sure to write about them in the comments. Thank you.

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The article presents current state technologies for the production of products from composite materials, including information about the technologies used, software, equipment for creating matrices, equipment for creating composite products, equipment for controlling product geometry and non-destructive testing.

composite materials

software

equipment for creating a matrix

1. Modern composite materials / ed. P. Krok and L. Browman; lane from English – M., 1978.

2. Construction and strength of fiberglass hulls and ship hulls. Foreign shipbuilding in 1965 – 1973 // Shipbuilding, 1973.

3. Frolov S.E. Methods for creating new macro-inhomogeneous composite materials and technological solutions for the manufacture of hull structures from them // Shipbuilding No. 3 2003, p. 55-59.

4. CAE – technologies in 2012: review of achievements and market analysis. – CAD/CAM/CAE Observer #4 (80) / 2013.

5. Interview with V.A. Seredka and A.Yu. Sofronov to the magazine CAD/CAM/CAE Observer #2 (78) / 2013.

6. Smart technologies for the aircraft industry. Increasing the competitiveness of domestic aircraft manufacturing enterprises using the example of joint projects of the Solver company and JSC VASO // CAD and Graphics, No. 1. 2011. P. 56-62.

7. Lukyanov N.P. Experience in using composite materials for the construction of PMO ships // Shipbuilding. No. 3. 2007. pp. 19-26.

A composite material is a material whose structure consists of several components with different physical and mechanical properties: metallic or non-metallic matrices with a given distribution of strengtheners in them, their combination gives the composite material new properties. According to the nature of the structure, composite materials are divided into fibrous materials, reinforced with continuous fibers and whiskers, dispersion-strengthened materials obtained by introducing dispersed particles of hardeners into the matrix, layered materials created by pressing or rolling dissimilar materials.

Today, composite materials are especially in demand in various industries. The first fiberglass ships were made in the second half of the 30s of the twentieth century. Since the 50s, fiberglass shipbuilding has become widespread in the world; a significant number of yachts, work and rescue boats and fishing vessels, landing craft, etc. have been built. One of the first applications of composite materials in aviation was the manufacture of carbon fiber reinforced plastic panels in the trailing edge of the wing of the F-111A aircraft in 1967. IN last years In aerospace products, you can increasingly find structures made of a three-layer “sandwich” with aluminum honeycomb core and carbon fiber skins. Currently, about 50% of the total weight of a Boeing 787 or Airbus A350 aircraft is made up of composite materials. In the automotive industry, composite materials have been used for quite a long time, mainly the technology for manufacturing aerodynamic body kits has been developed. Composite materials are used to a limited extent for the manufacture of suspension and engine parts.

However, until recently, enterprises used mainly manual laying out of parts from composites, and the serial production of products did not require deep automation of processes. Today, with the development of competition in the market, it is impossible to do without modern means design and pre-production, as well as without efficient equipment for working with composites.

Technologies for creating products from composite materials

In most cases, a chemically cured thermosetting resin is used as a binder filler, the curing process is characterized by exothermic chemical reaction. Mainly polyester, epoxy, phenolic and high temperature resins are used. Most often, in the manufacture of parts with complex configurations, technologies are used, the essence of which is to lay out a “dry” base followed by impregnation with a binder composition (“wet” molding, winding, injection, Resin Transfer Molding / RTM) or alternately laying out a “dry” base with film adhesive (vacuum impregnation, Resin Film Infusion / RFI). There are several basic technologies for manufacturing parts from composite materials, including manual and automated methods:

• impregnation of reinforcing fibers with matrix material;
• formation in a mold of reinforcement tapes and a matrix obtained by winding;
• cold pressing of components followed by sintering;
• electrochemical coating of fibers with subsequent pressing;
• deposition of the matrix by plasma spraying onto the hardener followed by compression;
• batch diffusion welding of monolayer tapes of components;
• joint rolling of reinforcing elements with a matrix, etc.

In addition, the technology for manufacturing parts using prepregs (semi-finished products consisting of a base material impregnated with a binder composition) has become widespread.

Software

The task of designing a product from composite materials is correct selection compositions that provide a combination of properties required in a specific operational case. When designing reinforced polymer composite materials, computer data processing is widely used, for which it was developed a large number of various software products. Their use makes it possible to improve the quality of products, reduce the duration of development and organization of production of structures, and solve the problems of their rational design in a comprehensive, high-quality and quick manner. Taking into account the unevenness of loads makes it possible to design a hull structure made of reinforced composite with differentiated thickness, which can vary tens of times.

Modern software products can be divided into two groups: those that perform batch analysis of laminates in a “two-dimensional” or “beam/plate” formulation and in a three-dimensional one. The first group is programs like Laminator, VerctorLam Cirrus, etc. The “three-dimensional” solution is the finite element method, and here big choice among available software products. There are various software products in the “composites modeling technology” market: FiberSim (Vistagy / Siemens PLM Software), Digimat (e-Xstream / MSC Software Corp.), Helius (Firehole Composites / Autodesk), ANSYS Composite PrepPost, ESAComp (Altair Engineering) and etc. .

Almost all specialized software from various companies has the ability to integrate with CAD systems high level- Creo Elements/Pro, Siemens NX, CATIA. In general, the work looks like this: the material of the layers is selected, the Common parameters package of layers, the method of forming layers is determined, the layer-by-layer method is used for the production of simple parts, for complex products zone or structural design methods are used. During the laying out of layers, their sequence is set. Depending on the method of production of the product (hand laying, molding, tape laying, fiber laying), a layer-by-layer analysis of the material is carried out for possible deformations. The composition of the layers is adjusted to the width of the material used.

After the formation of layers is completed, the user receives data about the product, allowing them to be used for various purposes, for example:

• output in the form of design documentation;
• use as initial data for cutting material;
• source data for a laser projector to indicate the contours of the pattern placement areas.

Go to modern technologies design and preparation of production of products allows:

• reduce the consumption of composite materials through the use of precise reamers and cutting machines;
• increase the speed and improve the quality of manual laying out of material through the use of precise blanks and laser projections of their laying areas;
• achieve a high level of product repeatability;
• reducing the influence of the human factor on the quality of manufactured products;
• reduction of qualification requirements for personnel involved in installation.

Equipment for creating matrices

Making a master model from wood is a labor-intensive and time-consuming process; to reduce the matrix manufacturing time and increase accuracy, the following are used: three/five-axis CNC milling machines, control and measuring machines or 3D scanners.

Gantry five-axis milling machine, (Figure 1), is available only to large manufacturers. Small companies use robotic milling systems on linear robot units (Fig. 2), or make master models from glued workpieces. In this case, a rigid hollow frame is taken as the basis of the workpiece, which is glued on the outside and then completely processed. Companies that do not have the opportunity to process the entire product take a different path: First, a simplified 3D model of the product is built in a CAD system using planes, and a rigid model is designed based on the simplified model. power frame from plywood. Then all outer surface is represented in the CAD system as cladding of the internal frame. The dimensions of the cladding are selected so that it can be milled on an existing CNC milling machine (Fig. 3). Then exactly assembled frame pasted over model cladding. With this method, the accuracy of the master model is lower and manual finishing of the cladding joints is required, but this allows you to create products whose dimensions significantly exceed the capabilities of existing CNC machines.

Rice. 1. Five-axis milling machine MR 125, capable of processing parts measuring 15x5 m and height up to 2.5 m

Rice. 2. Kuka robotic milling complex

Rice. 3. “Small” five-axis milling machine

Equipment for creating composites

The first step in mechanizing the molding process was the use of impregnation machines, which, in addition to impregnation, collect glass fabrics or fiberglass into multilayer bags with a total thickness of 4 - 5 mm. To mechanize processes, reduce the likelihood of personnel error, and increase productivity, for example, the spraying method is used, with which you can obtain external cladding, bulkhead panels and other fiberglass structures. The spraying method makes it possible to obtain molding angles by mechanization and provide higher labor productivity compared to molding angles manually molded from strips of fiberglass or fiberglass. The next stage in the development of the production of composite products is the introduction of an installation for automated winding of carbon-glass fillers. The first "robot" designed for laying dry fabric roll type was demonstrated by the American company Magnum Venus Plastech. For the first time in Russia, such equipment was introduced at JSC VASO. This equipment makes it possible to produce composite parts with a length of up to 8 m and a diameter of up to 3 m (Fig. 4).

To facilitate manual laying of fabric and reduce waste, cutting machines are used to automatically cut fabric/prepreg, laser projectors LAP and LPT for contour projection when laying out prepreg on production equipment. Using the laser projection module (Figure 5), it is possible to automatically generate projection data directly from the 3D model composite product. This way of working significantly reduces time costs, increases process efficiency, reduces the likelihood of defects and errors, and makes data management easier. The “software - cutting machine - projection laser” complex, compared to traditional laying, reduces the labor intensity of cutting by about 50%, the labor intensity of laying out by about 30%, and increases the utilization rate of materials, that is, you can save from 15 to 30% of material.

Molding carbon fiber reinforced plastics using the winding method makes it possible to obtain products with the highest deformation and strength characteristics. Winding methods are divided into “dry” and “wet”. In the first case, prepregs in the form of threads, strands or tapes are used for winding. In the second, the reinforcing materials are impregnated with a binder directly during the winding process. Recently, equipment has been developed that uses computer systems. This makes it possible to produce tubular products with bends and irregular shapes, as well as products with complex geometries. Equipment for winding using flexible technology, when reinforcing fibrous materials can be laid on a mandrel in any direction.

Rice. 4 Machine for automated winding and laying out of carbon-glass fillers Viper 1200 FPS from MAG Cincinnati

Rice. 5. Laser positioning system (green outline)

Equipment for monitoring the geometry and internal structure of the product

The contours of products often have curvilinear generatrices, which are not possible to check using traditional “plaz” methods. Using 3D scanning, you can determine how closely a physical sample matches a 3D computer model. For 3D scanning, you can also use an arm-type coordinate measuring machine (CMM) or a non-contact optical/laser scanning system. However, when used, non-contact scanning systems generally cannot work correctly on mirrored and high-gloss surfaces. When using “measuring arms”, several successive reinstallations will be required, since the working space, due to the design of measuring arms, is usually limited to a sphere with a radius of 1.2-3.6 m.

Also fiberglass materials There are a number of problematic areas. One of the main ones is quality control. finished product(lack of air cavities) and corrosion during operation. For non-destructive testing of ship hulls made of composites, X-rays are widely used, but efforts are being made to reduce them for a number of reasons. Recently, publications have begun to appear describing the detection of delaminations using infrared thermography (thermal imagers). At the same time, both thermal imaging and X-ray NDT methods detecting delaminations do not allow measuring their sizes and determining the depth of defects in order to assess their influence on changes in strength characteristics.

Conclusion

Currently, intensive development of automation of assembly of composite products, including equipment for creating matrices, is almost just beginning in Russia. Most often they only perform individual elements aerodynamic body kit for “tuning” cars. The implementation of the FiberSIM system at the Srednevsky Shipyard during the design and construction of the base minesweeper Project 12700, as well as at VASO, an automatic fabric laying machine, is a success. But these are individual examples; to increase competitiveness, it is necessary to comprehensively introduce new technologies.

Bibliographic link

Chernyshov E.A., Romanov A.D. MODERN TECHNOLOGIES FOR PRODUCTION OF PRODUCTS FROM COMPOSITE MATERIALS // Modern high technology. – 2014. – No. 2. – P. 46-51;
URL: http://top-technologies.ru/ru/article/view?id=33649 (access date: November 25, 2019). We bring to your attention magazines published by the publishing house "Academy of Natural Sciences"

T composites technology solves the problem of obtaining strengthened materials. The word technology comes from two Greek words: techne - skill and logos - word, teaching. Usually in names of this type the second part “logy” corresponds to the concept of “science”. For example, zoology is the science of animals, geology is the science of the structure of the Earth. By analogy, technology should be defined as the science of craftsmanship.

Composites technology – section of materials technology

But the word “science” next to the word “technology” appeared relatively recently. Technology is usually defined as a set of methods. If we're talking about O materials technology, then this is a set of methods for obtaining and processing materials.
Fibers as components of a material. Just a few decades ago one could agree with this definition. And today it undoubtedly requires clarification. Today, materials technology is not only a set of methods, but also the science of obtaining and processing materials, which has its own theoretical basis (the theory of metallurgical processes, the theory of pressure treatment, the theory of heat treatment, etc.), its own research methods, its own principles. And the creation of new materials is unthinkable without using its achievements. But keeping this in mind, we should not forget about the first part of the word. After all, technology is also skill. And skill is akin to art. To become a good technologist, in addition to knowledge, you need to have ingenuity and ingenuity. And you still need talent. However, these qualities are not superfluous in any business. People from various specialties take part in the creation of materials. Materials theorists are physicists, chemists, mechanics who study general patterns behavior of materials. Materials scientists and technologists are specialists who use these patterns to create new materials and develop methods for their production. They are the link between theory and practice. And there are also production technologists who work directly at factories and develop processes for producing products in industrial conditions. We will talk about the work of materials scientists and technologists.

Composites technology - a task for a specialist

Let's take for example Composites technology specialist. What problems does he have to solve? Here is one of them. Given: boron fibers wound on bobbins; aluminum (in any form - sheets, wire, powder, melt) can be chosen at your discretion. Required: connect fibers and aluminum matrix to each other, thereby obtaining high-strength boron aluminum. The technologist must decide how to do this. To make the conversation more specific, let's discuss how to obtain such a composite in the form of a sheet in which all the fibers are distributed evenly over the cross-section and laid parallel to each other. Solving a given problem means giving answers to three basic questions:

1. How to ensure fiber laying in a given direction?
2. How to introduce fibers into the matrix to obtain a sheet with the required structure and properties?
3. How to prevent softening and destruction of fibers during the manufacturing process of the material, while ensuring their strong connection with the matrix?

The question "how?" constantly pursues technologists. And always appears next to him constant companion- "Why?". Answer the question “why?” - means to find the reason causing this or that phenomenon. And the answer to the question “how?” must indicate ways to solve the problem. Every specialist involved in science is forced to constantly search for answers to these questions, and he has no hope of getting rid of them. As soon as you answer one, another appears, and it, in turn, gives birth to an avalanche of new “why?” And How?". And if they stop worrying, he ceases to be a scientist. But still, the main thing for a technologist is to answer the question “how?” This is his job. Three main questions are formulated that need to be considered when solving a technology problem. Let's try to answer them.

How to Orient Fibers in a Composite

Let's start in order. How to Orient Fibers in a Composite? If they were thick enough, like the steel rods with which they are reinforced, there would not be any special problems. You can place one at a time in specially prepared nests.
Fibers as the basis of composites. But we have to deal with thin fibers with a diameter of about 100 microns. In a sheet 5 mm thick and 500 mm wide there will be more than 100 thousand of them; manually laying each fiber in a place pre-designated for it is clearly an unrealistic task. A machine can do this. It should be taken into account that the fibers should not touch each other, they must be placed at a certain distance from one another to ensure the required concentration in the matrix. Here you can offer several options, but probably one of the best is the one that is widely used in practice today - winding method. Take a cylindrical drum, the circumference of which is equal to the length of the future sheet, and install it on lathe and wind the fibers onto it with a given distance. The idea is to then cut all the fibers along the generatrix of the cylinder and unfold them into a plane, resulting in one layer of parallel fibers. The length of this layer is equal to the circumference of the drum. And in order to save mutual arrangement fibers in a layer, you need to somehow fasten them to each other before cutting. You can, for example, coat it with glue and cut along the line after it dries. In this case, choose the glue so that, if necessary, it can be easily removed, say, burned off by heating.

How to introduce fibers into the matrix

But it's better to do things differently. Use the matrix material itself as a fastening agent. Then you can perform two tasks at once in order to properly maintain the composite technology: fix the fibers in the required position and at the same time enter them into the matrix, that is, to answer the second main question of our task. Not a bad idea. But again the same nagging problem arises - how? How to do it? You can’t get by without knowledge of physics and chemistry.

Electrochemical method

Can be used electrochemical method, applying a galvanic coating of matrix metal to the drum with fibers wound on it. This is not very difficult in principle, but:

1. takes a lot of time
2. not all metals can be applied this way,
3. It is difficult to ensure the desired matrix composition when it comes to complex alloys.

But for some composites, for example, with matrices made of copper or nickel, the method is quite acceptable. Although it would be better to find something more universal. You can come up with another way. Simply dip the drum with wound fibers into molten aluminum and, after removing, quickly cool until crystallization. It seems simple, but this simplicity is deceptive. The liquid metal will drain, and therefore it will not be possible to uniformly cover the entire monolayer with the matrix. In addition, in some cases, the molten metal can actively interact with the drum itself, corroding its surface and the surface of the fibers, and this is extremely undesirable, since the drum will lose its dimensions, and the fibers will soften and become brittle.

Plasma spraying of coatings

But the most suitable option. Use plasma spraying coatings. With this method, the matrix material is melted by a flow of low-temperature plasma (ionized gas with average temperature about 10,000 K), it is sprayed by the same flow and transferred to the surface of the drum, covering the fibers and filling the gaps between them. The plasma flow is obtained using a special device - a plasmatron, in which the working gas (nitrogen, argon, hydrogen, helium, etc.) is ionized under the action of an arc discharge. Although the plasma produced in conventional plasmatrons is called low-temperature, this “low” temperature (10,000 K) is quite enough to melt any of the materials existing in nature. Droplets of molten metal reach the cold drum and, giving off heat to it, crystallize, forming a uniform coating on the drum if it is rotated evenly. The material to be sprayed (in our case, aluminum) is usually introduced into the plasma jet in the form of a powder or wire. Externally the application process plasma coatings reminiscent of painting with a spray gun. Only instead of a spray gun there is a plasmatron, and instead of paint there is a matrix alloy. In principle, it is not necessary to use plasma for this purpose; you can get by with a gas torch or other device, but plasma spraying is very convenient and is widely used in the creation of composites. The reinforced monolayer obtained after spraying is cut along one of the generatrices of the cylinder and unfolded into a plane. The strength of the coating is sufficient to prevent the fibers from moving relative to each other, but not enough to ensure high strength of the composite. The thickness of the resulting monolayers is usually one and a half to two fiber diameters, that is, about 200 microns, and let me remind you, we need a sheet 5 mm thick. What should I do? Again, “how?”

Monolayer rolling

This time you don’t have to look for the answer for long: you need to do layered cake from the resulting monolayers, that is, collect them into a package of the required thickness and somehow compact them, connecting them inseparably to each other. This can be done, for example, rolling monolayers or hot pressing. In the first case, the package is heated in an oven and passed between rotating rollers. During rolling, the monolayers are connected into a monolithic material and the matrix material in each monolayer is compacted, which leads to an increase in the strength of the matrix and the strength of its bond with the fibers.

Hot pressing of monolayers

Sometimes it is more expedient to compact packages of monolayers not by rolling, but hot pressing. To do this, they are placed in a mold, the length and width of the working plane of which corresponds to the dimensions of the monolayers, and pressed from above with a punch. The mold is heated so that the required process temperature can be achieved. The heated bag is compacted, hence the name - hot pressing. In order for a strong bond to form between the monolayers and for all the particles of the deposited matrix metal to weld together to form a monolith, it is necessary to hold it under pressure, thereby allowing diffusion processes to do their job. It is these processes, together with pressure, that provide high mechanical properties our layer cake. That is why this method of producing composites is sometimes called diffusion welding.

Composite technology in the form of a rod or complex profile

In relation to the task at hand, we answered the second question - how to introduce fibers into the matrix. But what if you need to get a composite in the form of a rod or complex profile? Another “how”. You can again resort to rolling of monolayer bags, only not in smooth rolls, but in calibrated ones, that is, having special cuts that correspond to the required configuration. Or you can use the so-called liquid phase methods, when the matrix is ​​in a liquid state during the production of the composite. The fibers, unwinding from the spools (the number of spools is equal to the number of fibers in the composite), pass, without touching each other, through a bath of molten matrix metal, are wetted by it and enter a die, which forms a rod of the desired cross-section. After this, the rod is cooled, the matrix metal hardens, forming a composite material with the fibers. In this way it is possible to obtain rods of a wide variety of profiles. Products with complex profiles, such as turbine blades, can be conveniently produced by impregnation. Fibers are placed into a casting mold, the working cavity of which corresponds to the shape of the blade (how to do this is a separate issue that we will not consider now, but it can be done, although not easily), and then liquid matrix metal is poured into the mold. The gaps between the fibers are usually small, and it is difficult for the molten metal to fill them, but they need to be filled as quickly as possible so that the fibers do not have time to dissolve in the matrix. Therefore, in most cases, impregnation is carried out under pressure. The casting mold is evacuated, and liquid metal enters it under atmospheric pressure. As a rule, a pressure difference of one atmosphere is sufficient for fast and reliable impregnation. But this is only the case when the fibers are wetted by the molten matrix metal. If this does not happen, action must be taken. For example, carbon fibers are not wetted by liquid aluminum, so it is not possible to obtain carbon-aluminum by simply impregnating graphite threads with aluminum. But if you first coat these threads the thinnest layer chromium or nickel (it is enough to apply a coating one micrometer thick), which are well wetted by aluminum, impregnation will be ensured and a composite can be obtained. The main occupation of a technologist is to answer the question “how?” How to do it? Correct answers to this question can be given if the answers to the question “why?” are known. If you imagine a car mechanic who knows how to tighten bolts and nuts, but does not know the structure of the car. He's worthless. Likewise, a technologist who does not understand the physics of the processes occurring when obtaining a material is an inferior specialist. For example, a technologist knows that in many cases, after heating, the composite softens. The problem immediately arises - how to deal with this? This question is similar to the third “how?” posed at the beginning of the conversation. And to solve this problem, you need to know why the softening of the composite occurs. The answer to these questions is provided by composite technology.

Robotic complex For machining products made of composite materials are designed for mechanization and automation of some of the most labor-intensive operations in the technological cycle:

• Trimming and removing technological flash
• Milling grooves, recesses and positioners for embedded elements
• Drilling and milling through holes of complex shapes
• Milling through holes large sizes(window openings, hatches, etc.)

Robotic complex allows you to provide the following benefits:

• Increased processing speed compared to manual methods
• High repeatability and processing quality
• Milling with high quality"one pass" edges
• Improving working conditions
• Creation of additional knowledge-intensive jobs

At contact method During molding, the glass material is manually impregnated with resin using a brush or roller. Impregnation can be carried out simultaneously with rolling in the mold, or separately. Rolling is carried out to remove air from the laminate and uniformly distribute the binder.

Composite materials are materials created from several components. They are mainly made from a plastic base, reinforcing filler, and some other substances. As a result, the composite is characterized by high strength, rigidity and many other useful properties.

Polymer composite technologies are methods for creating materials whose matrix is ​​a polymer. They have a huge number of types and species, which ensured their prevalence and popularity. The following types of ceramic polymers exist:

Fiberglass;
carbon fiber reinforced plastics;
boroplasty;
organoplastics;
polymers filled with powders;
text slabs.

Composite ceramic materials are used in a wide variety of areas, among which are the following:

Construction;
electrical engineering;
chemical industry;
road construction;
telecommunications;
aviation industry, etc.

The prevalence and popularity of composite technologies is associated with many advantages this method production of materials. It is worth paying attention to the following positive qualities:

Improved physicochemical characteristics;
quite low specific gravity;
resistance to corrosion, rotting or warping;
low toxicity when burning;
non-flammability or difficult flammability;
unique chemical resistance;
low coefficient of linear expansion due to the action of heat;
fairly wide temperature range of functionality;
high electrical insulating properties;
increased environmental cleanliness.

IN XXI century Composite materials based on ceramic polymers have become one of the quite popular substances used to solve various technological challenges in a wide variety of fields, both construction and engineering or other types of industries. This was achieved with the help of many advantages that distinguish composites from other types of materials popular until this time.

Restoring the diagonal pump wheel

Composite materials can also be used to restore the diagonal pump wheel. With a similar request for repair of the pumping device Wastewater Under the name KSB Sewatec, the Angarsk Vodokanal MP approached the Ceramet company.

Over three years of operation, the pump's performance dropped to 70%, starting from the first day of operation. The repair included metal restoration, application of composite material, and dynamic balancing. Thus, due to the use of composite technologies, it was possible to extend the life of the pump and achieve cost savings of 4.5 times.

Features of the Ceramet material

Ceramet composite ceramic materials are designed to protect equipment, extending its service life and increasing its operating life. This significantly reduces downtime and the need to purchase additional spare parts.

The peculiarity of the Ceramet material is its fairly wide range of applications, which includes:

Repair pumping equipment;
renewal of augers;
improving the functionality of heat exchangers;
repair of pipelines, gutters, etc.

Thus, Ceramet composite material can be used for many different purposes, which is more advantageous than other equipment renewal methods.