Composite materials are spreading across the traditional markets and creating new ones due to the unique properties of structures obtained by using a combination of materials with different properties. Skoltech CMT Laboratory of Composite Materials and Structures explores modeling, fabrication and analysis of the composite materials and structures starting from manufacturing to usage and utilization. In order to achieve successful design of composite structures we conduct in-depth research in such areas as: simulation of technological processes; basic material behavior; stress, strain and failure analysis in both the static and fatigue regimes.
The Pultrusion process is a highly automated continuous fibre laminating process producing high fibre volume profiles with a constant cross section. Having a high fibre volume fraction makes pultrusion an ideal process for structural component production giving a high strength to weight ratio. Skoltech pultrusion machine is produced by Pultrex Ltd from UK (https://pultrex.com). Skoltech pultrusion machine is supplied by infra-red ovens and special systems for production of thermoplastic profiles. Characteristics: The maximum pulling force – 6 tons The maximum width of the manufactured profile – 500 mm Maximum feeding speed – 5 m / min Number of heat control zones – 6
Laboratory-Platen-Press Collin P 300 P/M
Compression molding is a high volume molding method that yields fast cycle times, high part uniformity, and allows for metal inserts, ribs and bosses to be molded in the part. In the compression molding process, the heated matched metal mold set is mounted in a large hydraulic press. A pre-weighed charge of molding compound is loaded into the mold and the press is closed. Under the pressure and temperature of the tool set the material cures rapidly. Subsequent machining and finishing operations are minimal in compression molding so labor costs are reduced. The laboratory plate press P 300 P/M allows to produce films and platens of all types of polymer. Touch screen control enhances the functionality and visualization of complex processes. Characteristics: Plate dimensions – 300 x 300 mm2 Max. force – 200 kN Max. temperature – 300 °C Heating rate – up to 15 K/min Cooling rate – 30 K/min
Vacuum system for resin infusion and vacuum bagging Vacmobile 2S
The Vacuum Infusion Process (VIP) is a technique that uses vacuum pressure to drive resin into a laminate. Materials are laid dry into the mold and the vacuum is applied before resin is introduced. Once a complete vacuum is achieved, resin is literally sucked into the laminate via carefully placed tubing. The Vacmobile 2S is a single pump/single resin trap modular mobile vacuum system for manufacturing composites using processes such as resin infusion and vacuum bagging.
Characteristics: Vacuum pump ‑ single phase powered continuousduty oil sealed vacuum pump VSV-20. 50 Hz capacity 20 m3/h(11.8 cfm) Vacuum level – Adjustable from 20% vacuum (800 mbar absolute) to the pump’s maximum vacuum: 0.5 mbar Resin trap ‑ 1 RT19 resin trap, with machined aluminium lid
The winding machine ensures the formation of the power shell of the product by layer-by-layer application of dry or wet composite material on the surface of the technological mandrel. To distribute the composite material over the surface of the mandrel, the machine has 4 generalized coordinates.
Synergy of engineering science and digital technologies aimed at the development of a simulation-driven design of advanced materials, structures
Julia V Bondareva, Daniil A Chernodoubov, Oleg N Dubinin, Andrey A Tikhonov, Alexey P Simonov, Nikolay V Suetin, Mikhail A Tarkhov, Zakhar I Popov, Dmitry G Kvashnin, Stanislav A Evlashin, Alexander A Safonov. Polymers, vol. 15, no. 5, 2023, pp. 1214 https://doi.org/10.3390/polym15051214
Omar Alajarmeh, Allan Manalo, Wahid Ferdous, Ghassan Almasabha, Ahmad Tarawneh, Khaled Eayal Awwad, Alexander Safonov, Xuesen Zeng, Peter Schubel. Fatigue and Fracture of Engineering Materials and Structures, 2023 https://doi.org/10.1111/ffe.13979