Composites processing software (for engineers)
The R.a.i.l process
Through a Dual-Use Applications Program (DUAP)
funded by the US Army Armaments Research Development and Engineering Center
(ARDEC), a team comprising UD-CCM, ARL, and Alliant TechSystems developed
the rapid automated induction lamination (RAIL) process to fabricate carbon/thermoplastic
(AS4/PEI) laminates in high volumes. The process relies on induction-based
rapid volumetric heating for multi-layer consolidation at high rates (5-10
ft/min has been demonstrated on 1-ft-wide panels). The team fabricated
an experimental laminator based on the RAIL process with hardware specifications
generated using a model-based design approach. Process optimization and
proveout were followed by factory implementation and proveout at the Alliant
Techsystems facility in West Virginia; the process is completely automated
with on-line control. 
The RAIL Process was designed
from concept
with COMPROSOFT
Full translation of mechanical properties
was demonstrated in comparison to baseline processes, such as autoclave
and vacuum debulk, with an order of magnitude increase in throughput.
The factory laminator is currently in service and is producing high-quality < 1
% voids) laminates, with zero disposable waste during the process. The
RAIL process reduced labor costs by 78% as compared to the baseline process
scaled to the required output. This illustrates a significant environmental
and cost improvement over conventional processes, where disposable waste
per laminate accumulates in significant amounts for high-throughput applications.
The RAIL Process was designed
from concept
with COMPROSOFT
The RAIL process has significant potential
as a cost-effective replacement for conventional (autoclave, vacuum debulk)
processes for carbon-fiber-based thermoplastics, as it is independent
of the resin system, and has the potential to be integrated with thermoforming
for high-volume production of net-shape carbon/thermoplastic parts. The
process was developed to fabricate the M829E3 sabot and has potential
applications in a variety of other areas.
The R.A.I.L. Process Rapid Automated Induction
Lamination process was invented at the Center
for Composite Materials (CCM) using COMPROSOFT. It is a unique
process that merges a number of technologies to produce composite laminates
are very high production rates.
The main driver to this process
is the use of induction welding technology that was used to rapidly heat
and consolidate composite laminates up to 10ft/min, and with the
proper control system could easily be extended higher. There is no limit
to the size of parts that can be made except for external physical conditions
which may limit the maximum consolidation forces that can be applied
to the laminate. We currently manufacture sheets 11" wide but there
is no limitation as we are aware of that could prevent this process being
scaled up to much larger size material.
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