Any interesting products or processes going on? This forum has been slow lately, so just trying to get some discussion going.
Could use some opinions on my project.
http://www.compositeforum.werksberg.com/showthread.php?p=22133#post22133
:rolleyes:
I’ve been spending the last 2 months heavily on induction welding CF/PEEK stringers and panels together for Fibreforge. Having to design and test many coils on several style of welds, is getting old. That and waiting 20min per weld.
Infused a work desktop for my wife since we have no office…and shew as using a plywood lap table. Hey, scrap fabric.
Also given up on a crap autoclave that is destroying my bag seals by super heated steam. Oh but nooooo, even though there is WATER in the autoclave being heated to 720f, it’s not the problem…it’s my bag.
grrrrrrrrrrrrrr
Lots of new molds and not much parts!.Finishing a set of doors for a drift supra.Starting molds this weekend for all 4 doors off a classic impreza and a batch of 12 rear spoilers.freezing cold here so costing a fortune to try and heat the workshop.here`s a pic of one of the molds for the inner side of a supra door.
Just screwed up a roof! My scissors fell out of my hand and made a hole in the bag 
Other than that it is normal here. I am making 2 more roof molds today. I am flanging them right now
[QUOTE=riff42;22137]I’ve been spending the last 2 months heavily on induction welding CF/PEEK stringers and panels together for Fibreforge. Having to design and test many coils on several style of welds, is getting old. That and waiting 20min per weld.
Welding CF/PEEK? Shows how much i know… what is PEEK? and how is it possible to weld CF? 
PEEK is a thermoplastic resin, which has a VERY high service temp (I think 400-500f?), resistance to most everything, and is a good anti-abrasion plastic. Sometimes PEEK is used in artificial joint sockets, and other body inserts. Unfortunately the process temp is about 720f…so most places can’t handle that.
Induction welding is basically taking a high power radio frequency pumping it into a coil, and the carbon fibers, being conductive, will induct into the RF field, get excited, and heat up. Like an induction cook top, or the way they treat steel items sometimes, VERY VERY quick heating. So the CF heats, melts the resin, and poof…process as needed.
PEEK = Poly Ether Ether Keytone.
Lots and LOTS of aromatics there.
I have been working on some metal tooling for rocket bulkheads. I cycled the tool this past week and the first part has stuck something awful. I have spent the past few days putting the tool into the freezer for a few hours then putting it on top of the heater for a few hours.
I fear it will get ugly.(sigh)
I took on my own workshop recently, we do all manner of work on our chosen type of car and haven’t had time for the composite part just yet, I’m working on it though!. I’ve been trying to get a pump for good money, but have so far failed, got my eyes on one right now though. We made a laying up bench frame from some timber and some cheap (slight damage) worktops to top it off, it’s 10’ x 4’ so a decent size. I got some scaffold for a rack, but haven’t made it up yet.
Like Deetech mentioned it’s real cold here this winter - the hardest for many years (still nothing by some US areas), most kids have never seen anything like it. The global warming protesters have been very quiet…
I got myself a waste oil powered heater so am nice and warm for nearly nothing. 
I’ve just been reading other peoples posts and looking at their pics to keep my interest up and try to learn some more, so a big thanks to everyone who takes the time to do this, the question answerers, teachers and posters of their own projects and methods are the kings of any forum.
I just bought Adtech: Suface coat, tooling clay (2 gallons), ProBuild Epoxy (medium hardner).
Not sure weather Im going to use the mold for RI, or plain old bagging.
Already did a test release on my shotgun stock plug. Pulled fine. As soon as this stuff shows up Ill be working Ill be posting pics.
a link to a description and usage of these Adtech products? Sounds interesting
Someone forget to release coat it? I’ve had so much variety on pulling parts off molds. Al and Steel, shiny or milled surface. Some stick, some pop off. So random!!!
And my aromatic, you mean the smell? PPS is worse, by a LOOOOONG shot. Unless you burn the PEEK.
Bought it all from this guy: http://www.theengineerguy.com/
Found them on Adtechplastics.com
Nothing special about the surface coat. Normal room temp stuff. The epoxy I ordered is 900cps, if I heat it I should be able to use it for bagging or RI. The tooling clay is the cool stuff. Lets you make quick, distortion free, epoxy molds.
Theres a good tutorial on how to use the stuff on freemansupply.com
Aloha,
I got the part off the tool and inact!
There were multiple coats of releasomer in place. I suspect there was part-grip on the tool. I am going to build up the edge of the tool a bit with JBWeld, then take a file to bring it back to net shape, but making sure there is a good draft angle at the edges.
I’m going to build a CF mountain bike this summer…
I’m still working out the frame geometry in SolidWorks. I’ll have a foam core waterjet cut in 2d from 2" foam. From there, I’ll hand shape the core to form the rounded tubing shape I want.
Still working on the exact layup orientation and number of plies in given locations. I’m very interested in swaged/taperwall aluminum tubing used in high end bikes, and want to implement those elements into my design. To that end, I’ll do a number of test tubes to determine exactly what I have to do for my design.
Does Solidworks have layup sims? I know Dasult’s(sp?) other program CATIA has some layup sims to perfect things like that. Of course, it’s way over my head to know HOW it works.
Just got back tonight from an overseas trip looking for more composites business. It’s pretty much a sealed deal, after working out the financial aspect.
It’s surprising to see how underdeveloped some places of the world still are. Met with the CEO and a Director of Production for a large manufacturing company, that is currently making some large parts with sheet aluminum. They’ve been experimenting with making composite sandwich structures with little sucess. (I’ll only say it involves pre-made low quality CSM laminates, and attempting to glue onto both sides of a foam sheet) When I presented an infused fiberglass panel with foam core, they were amazed.
Bumpy flights suck though.
Not my project, but someone showed me a wonderful new fabric that I doubt is being produced yet. It’s a standard 5.9oz carbon plain weave, but with every 5th or so tow, an infusion yarn. There is also apparently a thermoplastic binder, so you mold, heat up, it binds the layup together.
Infuse in the yarn direction, and you don’t need distro media!!
It’s beautiful!
I personally have given up on the autoclaving PEEK panels due to 7 bag/tape failures, which of course, was told was my fault. (No, not the fact that I pulled several good panels BEFORE the clave started to leak water.)
Still working on the welding though. Going to pot the coil in ceramic, and figure out jigs and how the hell to tell the surface temp!!
So your layup would consist of normal cloth, and then the final layer would be the cloth mentioned above?
from what I see walking through the labs all the time, no, use this fabric for all layers.
makes me wonder about if you need to do 45’s and 0/90’s, or special areas around fastening areas, or holes.