Question 1 What happens to the material if its degree of polymerization increases? Is it a bad or good thing?

Is there a limit while increasing the DoP of a material?

Question 2

Above figure shows the relation of the epoxy between the viscosity and time After adding the curing agent into the resin during the manufacturing, it is expected that the viscosity of the material increases but instead, it is seen that the viscosity of the polymer is decreased. Why?

Question 3 What does racetracking channel serve for? Why is it used in composite manufacturing? Are there any disadvantages while using racetracking channel?

Question 4

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An RTM problem is shown above picture, and it is known this problem is not caused by a careless labor. What are the reasons for this manufacturing error?

Question 5 A random mold is used to manufacture a composite. To monitor the process, sensors are used. How(not where) should the sensors be placed on the mold? Explain the logic.

Question 6 In VARTM, only one side mold is used and a vacuum bag is used for the other side. Is it safe to use a bag? Will it contain the resin without a problem? Show it by calculation. (Vacuum pressure is 90%.Vacuum bag should have 10kN force on it to maintain the safety of the process)

Question 7 A circular composite material of a 0.45 Volume fraction is manufactured by VARTM. 5 layers are used in the process. (dfiber =2524 kg/m3, dareal= 0.3 kg/m2 ,dresin= 1094 kg/m3 , r=0.23 m) a) Calculate the thickness of the resin. b) Calculate the the the Mass of the Porous Part. c) Calculate the amount of the resin in the pipe which is used to transfer the resin into the mold.

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d) Calculate the total amount of the resin required and a filling time (assuming the mold is empty )for a 0,2 cm3/sec flow rate.

% Cobalt (1% Cons) (weight base) 0.6 0.6 0.6 0.6

% Butanox (MEK-P) (weight base) 1 1.2 1.5 2.5

Gelation Time (min) 50 40 30 20

e) After calculating the filling time for the process, choose correct Cobalt-Butanox percentage to add into the resin.

Question 8 a) Write down the pseudo code of a constant flow rate machine for a manufacturing process. The code must prevent the machine exceed 100 kN. Force is a function of flow rate and the volume filled in the mold. b) Draw two graph assuming the force limit is reached in the half of the process time. i) Force versus time ii) Flow rate versus time Hint: Assume the relation between force&time and flowrate&time as linear.

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