If you have ever wondered how some of the parts of vehicles, nautical parts or even aerospace components are manufactured, then you need to know about advanced composites. Composites are parts constructed extremely strong, lightweight and durable. The benefit of using composites material instead relying solely on metal are numerous. They save energy in both the production process and are lightweight saving energy in the long term. Additionally, advanced composite parts help to reduce emissions. A good example of a sophisticated advanced composite application is it’s use in MRI Suspension Systems.
The overall process of the concept of design to final delivery is somewhat in depth.
The initial phase of creating the concept begins with research and technology. The design and development of the idea is then put into action along with an advanced analysis. Next comes the testing and qualification of the concept itself. These steps are all part of the first process of designing the initial composite design according to the specifications agreed upon by the client and the company hired to complete the project.
The second phase of the advanced composite production is the actual manufacturing process. This process like the first phase, has a number of steps. The first is the advanced automatic fibre placement. This process is the development of new fiber placement strategies for complex parts. The second phase of the production process also consists of automated processing, curing and thermosets and thermoplastics.
The third step of the advanced composite production entails precision machining. This is an important process of the making of the composite product itself. Parts during this phase are meticulously fitted and machined into place. We also see precision machining work on cars, boats and vehicles of various nature. The machining process on composites is performed by highly qualified machinist who specialize in this work.
The fourth step of the process of making an advanced composite entails having the product tested for quality assurance. This step consist of the concept of assuring the product adheres to the norm standards set forth for the specific product. A prime example of quality assurance is the process medications are required to be produced by and the standards set concerning delivery and manufacturing. An advance composite is required to meet the guidelines set in place for quality assurance before final delivery.
The final two steps in the production process of advanced composite production consists of auxiliary procurement of parts and finally, delivery. All of the above steps must be taken before the composite itself is sent to the client, ensuring a product free of defects finds it’s way to it’s owner. While this may seem like a lot of steps to ensure a high quality product, when dealing with advanced composites, quality can never be compromised.
The above listed are the main steps taken on the road to a quality assured professionally made advanced composite. Composites are often used when the use of metal alone would be ineffective both in it’s final production and in production itself.
The composites are used in the production of aerospace designs and aircraft. Using lightweight materials in the production of manned ships designed to withstand extreme outside pressure at high altitudes is crucial to the success of flight. Additionally, you may find a vast array of advanced composites in race cars designed to withstand heat, friction and the elements when in high speed races. Military aircraft also use composite material in certain designs. While the reasons for using the composite material may be to make the craft lighter and sturdier, there are other significant reasons advanced composite materials are used in their production.
The actual materials used in the production of composites are pretty amazing in themselves. While it would be difficult to list all of the components used in the making of advanced composites, metals like Titanium alloy, stainless steel and cold worked steel of common in the production. You will also see different types of epoxy used in the creation as well. Other variables that come into play in production such as weaving direction. For someone who is not familiar with the process, it can seem like a difficult procedure. With this said, a composite engineer may very well be your best source of additional correct information.
Composite materials as you can see are used in a variety of applications. They have also proven themselves to be a cost effective way of building parts for different types of projects. They are lightweight, designed to not only withstand impact and the elements, but also have a durability ensuring a product last for years if not decades. Composite materials have been used for over forty years, however with the ongoing technology much needed in the design and production of composites, we’re sure to see much more innovation in the field.