CompositesWorld
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AUGUST 2015 36 CompositesWorld WORK IN PROGRESS Michael R. LeGault is a freelance writer located in Houston, TX, US., and the former editor of Canadian Plastics (Toronto, ON, Canada). mlegault@compositesworld.com process. Calloway says the development of process control for it can be broken down into a series of programming problems — for example, how to ensure that step B does not happen until step A has been completed. Growth of process control systems in composites will require, of course, the participation of those who manufacture molds, and Kistler's Lagonegro says the company's early marketing eforts will include toolmakers and fabricators. Calloway Carbon cuts its own tools so, in addition to owning the process control system, it also controls process setup. Calloway says the number, type and location of the sensors in the mold is part dependent. Almost all the company's tools are CNC-machined from aluminum. Many, Calloway reports, use two or more piezoresistive pressure sensors, located at the "top" of the tool. He calls the process of determining where to locate the sensors "part science, part art and part luck," based on years of experience. Prior to production, each tool is run through an auto-calibrate sequence. Process control monitoring will not initiate until sensors are set within predefned limits (the recipe) to permit cycle start. Calloway's software also allows production to be run in manual mode until the recipe is refned and mature. One of the more exciting develop- ments in composites is the prospect of system use in the mainstream automotive market, a scenario that is already begin- ning to play out. Molders with process control technology are likely to have a step up on others in their eforts to meet the auto industry's stringent, Six Sigma-based quality standards. Lagonegro says that while the composites industry hasn't been clamoring for process control, "from our perspective, it's the next big thing." as the "recipe." Once the recipe is under- stood, Calloway notes, it's simply a matter of replication. Te company has been using sensor- based, automated RTM manufacturing for about fve years. Calloway says the sophis- tication of sensor technology was crucial to successful development of its in-house automation technology: "Fortunately, sensor technology is really good right now at the commercial level." Just as signifcant, RTM could be the composites manufac- turing method that best lends itself to automation, because it is largely a sequential Read this article online | short.compositesworld.com/InMoldSens COMBINED LOADING SHEAR FIXTURE NO. WTF-NR-(CLS) V-NOTCHED RAIL SHEAR FIXTURE NO. WTF-NR ASTM D 7078 DR. DANIEL ADAMS, VICE-PRESIDENT STANDS BEHIND THE FIXTURES HE DEVELOPED… AND EVERY FIXTURE WE SELL. Expert consultation with Dr. Don and Dr. Dan • Over 40 fixtures in stock, ready to be shipped. • Email or call today to discuss your fixture and custom design needs. 2960 E. Millcreek Canyon Road Salt Lake City, UT 84109 Phone (801) 484.5055 Fax (801) 484.6008 email: wtf@wyomingtestfixtures.com www.wyomingtestfixtures.com Dr. Donald F. Adams President 50 years of Composite Testing Experience W T F yoming est ixtures INC. ANOTHER DR. ADAMS HAS JOINED US. TWO EXPERTS ARE BETTER THAN ONE