SEMINAR REPORT ON PULTRUSION PROCESS

MANIPAL INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL AND MANUFATURING

SUBMITTED BY

CHETAN P BHAT

080922016

PDF processed with CutePDF evaluation edition www.CutePDF.com

 Pultrusion Process

Introduction
Pultrusion is a continuous molding process using fiber reinforcement in polyester or other
thermosetting resin matrices. The process is similar to the metal extrusion process, with the
difference being that instead of material being pushed through the die in the extrusion
process, it is pulled through the die in a pultrusion process. Pultrusion creates parts of
constant cross-section and continuous length. Pultrusion is a simple, low-cost, continuous,
and automatic process.

Pultrusion is a continuous, automated closed-moulding process that is cost effective for high
volume production of constant cross section parts. Due to uniformity of cross-section, resin
dispersion, fibre distribution & alignment, excellent composite structural materials can be
fabricated by pultrusion. The basic process usually involves pulling of continuous fibres
through a bath of resin, blended with a catalyst and then into pre-forming fixtures where
the section is partially pre-shaped & excess resin is removed. It is then passed through a
heated die, which determines the sectional geometry and finish of the final product. The
profiles produced with this process can compete with traditional metal profiles made of
steel & aluminium for strength & weight.
The pultrusion process has developed slowly compared to other composite fabrication
processes. The initial pultrusion patent in the United States was issued in 1951. In the early
1950s pultrusion machines for the production of simple solid rod stock were in operation at
several plants. Most of these machines were
the intermittent pull type. In the mid-1950s,
continuous pull machines were available. The
late 1950s were producing pultruded structural
shapes and by 1970, there has been a dramatic
increase in market acceptance, technology
development, and pultrusion industry
sophistication.

The process provides maximum flexibility in

the design of pultruded FRP profiles. Currently,
profiles up to 72 inches wide and 21 inches
high are possible. Since the process is continuous, length variations are limited to shipping
capabilities. Specific strength characteristics can be designed into the composite, optimizing
laminate performance for a particular application by strategic placement of high
performance reinforcements. Color is uniform throughout the cross section of the profile,
eliminating the need for many painting requirements. Processing capabilities include the
production of both simple and complex profiles, eliminating the need for much post-
production assembly of components.

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The tooling required to start producing pultruded parts is fairly inexpensive and
straightforward compared to the complex and sometimes very costly molds that are
necessary for other plastics molding processes. It is worth noting though that open profiles
are generally less expensive to produce than hollow ones.
As a rule of thumb, parts with a small cross section can be manufactured at a speed of
roughly one meter per minute, whereas larger profiles will require up to ten times longer.
Pultrusion is a high-volume manufacturing process and most manufacturers will ask for a
minimum order of 500 meters to start production.

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Basic Raw Materials

One can use a wide variety of fibrous reinforcement and resin system to get a composite
material with a broad spectrum of properties by pultrusion process. Since each fibre and
resin material brings its own contribution to the composite, knowledge of raw material
properties is the first step in designing a satisfactory composite product. The reinforcement
provides mechanical properties such as stiffness, tension and impact strength and the resin
system (matrix) provides physical properties including resistance to fire, weather, ultraviolet
light and corrosive chemicals.

Reinforcement Types
Reinforcements serve as the primary load bearing entity in the part; reinforcements can
enhance functional performances such as electrical conductivity, radar cross section, and
thermal performance. In the process, the reinforcement allows the part to be pulled
through the die acting as both a load transfer media as well as the source of bulk, which
allows the die to be continuously, uniformly filled. Three characteristics must be considered
when choosing reinforcements:

first the fibre type (glass fibre, aramid and carbon); second the form (roving strands, mat &
fabrics) and third the orientation.

Based on Fiber Type

The glass fibre continues to be the most widely used reinforcement, because they are
readily available and comparatively cheaper. Electrical grade E-glass fibres, the most
common, exhibits a tensile strength of approximately 3450 MPa and a tensile modulus of 70
GPa, but they have relatively low elongation of 3 to 4%. A variety of fibre diameters and
yields are available for specific applications. Surface sizing of glass fibres provides optimum
impregnation and chemical bonding between the fibres and matrix resins, thus ensuring
maximum strength development and retention.

S-glass fibre exhibits high tensile strength (4600 Mpa) & tensile modulus (85 Gpa) and is
used for high-performance applications. The Carbon fibre exhibits tensile strength from
2050 to 5500 MPa and tensile modulus from 210 to 830 GPa with elongation of 0.5 to 1.5%.
Carbon fibre has various unique properties like electrical conductivity, high lubricity and low
specific gravity (1.8 versus 2.60 for E-glass).

Very tough composites having good flexural and impact strength can be fabricated by using
Organic fibres such as aramids, having high tensile strength (2750 MPa) and modulus (130
GPa) along with elongations of up to 4%. Polyester fibres with appropriate binders have
been used as a replacement for glass in applications that would benefit from increased
toughness and impact resistance but where tensile and flexural strengths can be sacrificed.

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Based on Form

Rovings
Rovings are continuous fibers, which are one of the primary reinforcements used in
pultrusion. Rovings come in three main forms; Conventional rovings, Single-End Continuous
Rovings or direct rovings, and bulky or texturized rovings.

Conventional Rovings

Conventional or multi-end roving is assembled from a number of forming packages into the
desired final yield or Tex. Conventional rovings are most commonly used in applications
containing large thickness of unidirectional reinforcement. Conventional rovings tend to fill
space at lower glass levels, giving a more resin rich cross-section.

Single-End Continuous Rovings or direct rovings:

Single-End Continuous Rovings or direct rovings are the

most commonly used reinforcements in the pultrusion
process. Single- End Continuous Rovings combine ease
of handling due to low catenary and fuzz, with highly
reproducible mechanical properties in both its standard
unidirectional usage and when used in stitched and
woven fabrics. Single-End Continuous Rovings are widely
used due their excellent processing, and laminate performance. Considerably higher shear
strengths are achieved with single-end rovings compared to conventional rovings

Bulky or Texturized Roving

Bulky, texturized, or fluffy rovings are specialty rovings

designed to fill corners in complex shapes, "clean" the
die, preventing formation of resin rich areas, which
could cause local spaulling. Bulky rovings are intended
to act as local filler, though they do provide some
reinforcement.

Mats, Complexes, and Veils

Mats, fabrics, and veils are used in pultrusion processes to give properties to the part not
achievable using roving reinforcement. Mats give the ability to develop off axis structural
performance, create a higher resin content part, and develop unique surface qualities for
both visual and non-visual attributes, such as corrosion resistance.

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Continuous Filament Mat

Continuous filament mat or swirl mat is the most common mat used in pultrusion.
Continuous filament mats (CFM) provide strength and stiffness in the transverse or non-
pulling direction of the pultruded part. They provide
a degree of bulk, which improves processing and
limits resin rich sections of the part.

This bulk also reduces the glass fraction required for

the processing of a specific cross section. CFM mat
also improves the shear strength of the laminate
produced. CFM used in pultrusion contains a fast-
wetting non-soluble binder that maintains mat
integrity through the preforming operations. It is
less prone to skewing (misalignment) common in
fabrics.

Mats are generally composed of coarse glass

strands, which are highly porous thus ensuring
complete wet out of each individual filament. The
roll is slit to the appropriate width of the part. The variation in slitting widths will cause
some variation in the localized reinforcement contents within the part; hence there will be
an impact on the mechanical strength. Weight variation (as well as resin variation) and
shrinkage will also induce variation in product characteristics.

Continuous strand mat provides the most economical method of obtaining a high degree of
transverse physical properties. The mats are layered with roving; this process forms the
basic composition found in most pultruded products. The ratio of mat to roving determines
the relationship of transverse to longitudinal physical properties.

Fabrics and Stitched Complexes

Fabrics and stitched complexes are the newest generation reinforcements for the pultrusion
process. The construction of fabrics can be tailored to give specific reinforcing properties to
the part in order to achieve the needed strength in parts with demanding design
requirements. When the mix of required physical properties is not satisfied by conventional
mat roving construction, selected fabrics can be used to meet the end use requirements.
Varieties of these products can be used by themselves or in conjunction with the standard
mat roving construction to obtain the necessary results. The fiberglass fabrics are available
in balanced, high longitudinal, high transverse or ± 45° multi-ply construction. Since these
materials are more costly, the composites using these reinforcements are more expensive
than standard construction pultrusion.

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Chopped Strand Mats

The use of chopped strand mats in pultrusion is normally

related to specific needs for improved surface or corrosion
resistance in flat or gently curved laminates. Care must be
taken in selecting a chopped strand mat for pultrusion, as
most existing products are not designed to handle the tension
associated with the pulling of the product through the
process.

Veils

Veils in the pultrusion process are designed to establish a high

quality surface layer on the pultruded part and protect the die
from scarring by the other reinforcements during the pulling
process. Veils can be materials such as spun polyester, glass
veil, and for special requirements carbon veils have been
used. In many cases the veils can have pre-printed designs and
logos, which become the part surface finish aiding the part
appearance. Since pultrusion is a low-pressure process,
fiberglass reinforcements normally appear close to the surface
of the product. These can affect the appearance, corrosion
resistance or handling of the products. The two most
commonly used veils are A-glass and polyester .

Matrix Choice
The resin matrix has several functions in a pultruded composite. The resin's basic functions
are to fill the space between filaments, to fix the strand alignment, and to distribute the
bonding and shearing stresses. Due to the much higher modulus of the glass, and its
normally high percentage of volume in the composite, the strength effect of the resin is
usually quite small. As in the case with all FRP/GRP material systems, the resin plays an
important role in determining the chemical and environmental durability of the total
system. It also controls the thermal, electrical, and visual

The composite properties such as high-temperature performance, corrosion resistance,

dielectric properties, flammability and thermal conductivity are determined exclusively by
the properties of resin matrix.

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Polyester Resins

Unsaturated Polyester resins are most commonly used in pultrusion. Orthophthalic,

isophthalic acids or anhydrides, in combination with maleic anhydride and various glycols,
are the basic elements. Pultrusion polyester has the ability to gel and cure rapidly to form
the strong gel structure required for release at the die wall. Generally resins with the
viscosities of 500 cP are used for pultrusion. Higher viscosity low-reactive monomer versions
can be blended with additional styrene to suit the processing need. The styrene level must
be properly maintained to achieve good cross-link structure without having residual
(unreacted) styrene in the finished composite.

Polyester resins exhibit good corrosion resistance to aliphatic hydrocarbons, water, dilute
acidic & alkaline environments. They do not perform well when exposed to aromatic
hydrocarbons, ketons, and concentrated acids. A high degree of unsaturation in polyester
chain exibits shrinkage up to 7% on curing. This level can be reduced using fillers and low-
profile additives. Composite based on polyesters retains high percentage of their electrical
insulation properties even if used continuously at temperature up to 200oC. Though
polyester supports combustion without modification, hence backbone bromination or the
use of additives greatly improves its flammability and smoke generation properties.

The electrical properties of polyesters make them suitable for use as primary insulators in
many high-voltage applications. Retention of electrical properties even at elevated
temperatures has made polyester insulators the materials of choice in many applications.
The weatherability of polyester is fair to good. Additional protection is usually through a
variety of ultraviolet absorption additives or using polyester surface veils and even painting
(done after pultrusion)

Vinyl Ester Resins

These resins are used when additional performance is sought. Vinyl esters (VE) offer better
corrosion resistance, higher mechanical properties at elevated temperatures, and improved
toughness properties such as impact and shear. They provide very efficient wet out and they
have higher temperature capability with improved flexibility compared to polyester resins.
The chemical structure of vinyl ester resins is such that the reaction sites are at the end of
each polymer chain rather than along the chain resulting in rigid segments along the
polymer backbone. This leads to lower-link density and high-temperature capability of these
materials. VE resins are superior to polyesters, but this advantage comes at a cost in two
ways:

1. VE resins can be as high as double the cost of polyester resins

2. VE resins usually run at speeds about 2/3 the speed of polyester due to their lower cross-
link density. Many VE have a narrow temperature window. A 10°C temperature change can
cause blistering in pultruded profiles. Operators should be aware of the small processing
window which VE resins have.

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Epoxy Resins

Epoxy resins typically offer the highest physical property performance as well as the best
strength retention at high temperatures of all the resins used in pultrusion. Epoxies are
frequently used for primary electrical insulation, aircraft, aerospace, and defence
applications. Epoxies can be used in continuous use applications at 300°F (150°C) and
epoxies provide increased flexural strengths and shear strengths when compared to
polyesters and VE. Epoxies have excellent corrosion resistance and electrical properties.
The disadvantages of epoxy resins can be:
• Poor toughness as a result of their rigid structure
• Can be more expensive to purchase
• Slower processing speeds vs Polyester and VE resins
• Lower pot life
• Mold sticking considerations
• More difficult to clean up
They require a higher reinforcement content than either polyester or vinyl ester

Other Resins

A variety of resin alternatives is also available for specific applications. The resins based on
Methacrylate Vinyl Ester Resins although expensive than polyesters but could be used for
their special properties viz. improved physical properties, very low viscosity which allows
them to be highly filled, rapid processing speeds, smooth profile surfaces and improved
flame retardancy and weathering. One concern with MVE is odor which plant personnel may
find objectionable.

Phynolic resins are also used in pultrusion owing to their high heat resistance and flame-
retardancy/low-smoke characteristic. Phenolic resins are suitable typically for pultruding
natural fibres such as jute.

A desire to improve toughness and post processing formability has lead to the use of
thermoplastic resins. The engineering thermoplastic resins provide excellent heat distortion
properties. The technology for impregnating fibres with thermoplastic resins includes hot-
melt application and solvent solution impregnation.

Filler and additives

Filler and additives are used to enhance specific performance, reduce cost, influence
viscosity, or improve processability of resin systems. Fillers can be incorporated into the
resins in quantities up to 50% of the total resin formulation by weight. ). The usual volume
limitation is based on the development of usable viscosity, which depends on the particle
size and the characteristics of the resin. There are three fillers frequently chosen for use in
pultrusion.

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These fillers are:

Calcium carbonate is the most popular and is used as a volume extender. Calcium carbonate
is generally used where performance is not critical.
Clay (alumina silicate) fillers are used for their corrosion resistance and in profiles requiring
electrical insulation. They can provide very good surface finish.
Alumina trihydrate is used when flame or smoke suppression is desired.
Calcium carbonate is primarily used as a volume extender to provide the lowest-cost-resin
formulation in areas in which performance is not critical.

Special purpose additives include ultraviolet radiation screens for improved weatherability,
antimony oxide for flame retardance, pigments for coloration, and low-profile agents for
surface smoothness and crack suppression characteristics. Mould release agents (metallic
sterates or organic phosphate esters) are important for adequate release from the die wall
to provide smooth surfaces and low processing friction. Pigments may be used to impart
color, weatherability, or flame retardency to the finished part.

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Components of Pultrusion Process

There are four components required in any pultrusion processing operation:
1. Creels
2. Forming or preforming guides
3. Resin impregnation systems
4. Primary die
5. Puller/clamping pads
6. Cut off saws

Creels
The creel should provide a position from which the
roving can be fed to the pultrusion process under
controlled and uniform tension. It also provides a
location for the transfer of the roving strand from
the running package to a second back-up package for
continuous uninterrupted production. There may
even be room for extra roving packages for
replacement or maintenance as required.

The size, shape and type of creel will normally be

determined by space considerations such as roving
package dimensions, the distance the strand must
be conveyed and the number of packages to be
handled. The amount of glass being used on a
continuous basis must also be considered.

The two common types of creels used are shown.

Each creel arrangement has a range of possible
number of packages for the best process efficiency:

Table creel - up to 50 packages

Bookshelf creel - 20 to several hundred packages

The bookshelf-type creel is the most common and

usually provides the best balance of accessibility
and maximum utilization of floor space. The size
will vary widely, but the creels shown provide a
standard module concept for creeling. Shown are
creels for handling 32 packages (16 active-16 transfer) in both a side pull and end pull
configuration. To handle different numbers of packages, the creels can be increased or
decreased in length or multiple creels can be used.

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In the end pull creel, commonly used in pultrusion, it may be necessary to guide each strand
within the creel using steel rods or ceramic guide eyes. This can prevent sagging and
whipping could tangle two or more strands on the same shelf.

Most pultrusion processes use stationary roving packages on bookshelf or table creels,
pulling the roving strand from the inside of the roving package. For some applications
requiring minimal strand twist for better wet-out and a flatter and wider strand profile,
pulling the roving strand from the outside of the roving package may be an option.

Forming guides
It is important to determine how the reinforcement is organized, aligned, and fed into the
primary die. Besides formulation and heating control, preforming system is also critical for
successful and constancy pultrusion. Before entering die, impregnated fibreglass rovings
and mats must be properly arranged and placed. Un-proper preforming system causes
failure of pultrusion, bad quality, and other problems.

Please note, preforming system is far from easy as most people think of. Firstly, it must be
designed based on profile design to meet the
physical requirements. Secondly, it must let
all reinforcements running freely and
smoothly, to avoid any breaking of rovings,
mats or cloth. Thirdly, for dies with
mandrels, the preforming system is the only
device to keep uniform thickness of
pultruded profiles. In-proper preforming
may cause eccentric and even breaking of
pultrusion. Fourthly, for complex profiles,
preforming system is a large challenge. A
preforming die gently shapes the material and removes all but about 10% of the excess resin
prior to entry into the pultrusion die.

There are two primary materials used in the

forming guide tooling: steel and ultra high
molecular weight polyethylene (UHMWPE).
The advantage of steel is that it is less
expensive (if carbon steel is used vs.
stainless) and standard plate, sheet, bar, and
rod can all be used.

A disadvantage is corrosion of non-stainless

steel and the difficulty to machine. The
advantage of UHMWPE is that it is lighter,
resistant to chemical attack, less damaging to the glass reinforcement, and therefore, easier

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to clean. A major advantage is that it is easy to fabricate, on-line, when modifications are
required. UHMWPE is easy to drill and machine slots for mat. A disadvantage is that
UHMWPE wears faster than steel. Except for the primary die the forming guides and the
guiding of the reinforcement into the die is the most important aspect in pultrusion
technology

Resin Impregnation System

The dimensions of resin baths are restricted to minimize the volume of catalyzed resin and
can be heated to control the resin viscosity to promote fiber wetting, although this will
reduce the working life of the bath. To facilitate lacing up, the roller assembly in the resin
bath is manufactured in two parts—a lower fixed set of rollers submerged in the resin bath
and a moveable upper set, under which the fiber is positioned. The assembly is then pressed
down to push the fiber into the bath to contact with the lower set of rollers. This system
facilitates an easy lace-up procedure and ensures good compaction to expel all air and
promote fiber wetting. Alternatively, the fiber can be passed over a drum upon which the
correct amount of resin has been metered and adjusted by a doctor blade.It is extremely
important to allow the resin and reinforcement enough time to fully wet-out. The
impregnation or bath system directly impacts wetout.

There are three resin impregnation systems available today.

They are:

1. Dip bath

2. Straight through bath

3. Resin Injection systems

Dip Bath

The dip bath, or open bath, has the

reinforcements travelling from the creels
down into the bath where the rovings go
through an "S" bar guide, which breaks apart
the roving bundle, allowing better coating of
the filaments by the resin. The bath system is typically used for all roving reinforcements, as
well as for simple mat and roving profiles where the mat can be handled horizontally, or
where taking the mat out of the horizontal plane will not induce a bow into the finished
profile. This system exposes a large amount of resin to the air and permits styrene
evaporation into the plant environment. Styrene emission is a environmental and health
consideration,which needs to be assessed with this impregnation system.

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Straight Through Bath

A straight through resin bath is a trough with

forming cards on each end. These cards can
also be used to begin the forming process. The
cards allow resin to leak from the open areas.
The excess resin is then collected and pumped
back into the bath trough. The advantage of
this design is the reinforcements are taken
from the horizontal plane, allowing the
profiles to be made with fewer tendencies to
warp or bow, and this design also reduces the amount of styrene released into the plant
environment.

Resin Injection System

The resin injection system is the newest

process for impregnation. With resin
injection, a steel chamber is attached to
the front of die. The chamber contains
port(s), which allow resin to be injected
into the cavity. The combination of cavity
design, resin pressure, and movement of
the reinforcement being pulled into the
die generate hydraulic pressure forcing
resin to penetrate the reinforcement
bundle, resulting in impregnation. With resin injection the resin is not open to the plant
environment, reducing the amount of styrene released into the workplace. Resin injection
systems require reduced clean up time, due to resin contact with fewer components. The
disadvantage of resin injection is the potential for incomplete impregnation of profiles with
thick walls, or incomplete impregnation in resin systems with high filler loading
incorporating a high number of mat or veil reinforcements.

Primary Die
The die is the heart of the pultrusion system and is the limiting step in production rate since
the part is both shaped and, usually, cured in the die. The processes of shaping and curing
along with the correspondent line speed are dependent upon the shape of the part, the
type of resin, the internal friction in the die, the heat expansion of the resin, the contraction
of the resin, and mechanical warpage which may occur in the part because of non-
symmetries in the fiber orientations.

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The opening of the die is usually somewhat larger than the final shape, permitting easy
collection of the fibers bundle, and then the die interior dimensions gradually reduce in size
until the final shape is achieved. During this shaping process, the part is cured.

Cure is accomplished either by

thermally heating the die (usually with
common electrical heaters) or by
subjecting the material to rf
frequencies. Both of these systems
have their advantages. The thermal
heating is simple and can be used with
metal dies, thus limiting die wear.
However, the poor heat transfer of the
resin means that as the thickness of
parts increases, the speed of the
pultrusion line must slow. Studies have
shown that thicknesses of about .5 inches can be thermally cured at 2 feet per minute but
that parts thicker than 3 inches cannot be cured at all using just thermal energies, regardless
of the line speed.

If rf curing is used, the thickness of the parts which can be cured and the line speeds
possible are both improved — about 3 times faster with parts that are .5 inches thick.
However, rf curing does not work well for metallic dies nor for conductive parts. Hence with
rf curing, non-metallic dies are generally used and these are prone to rapid erosion and poor
dimensional control. Parts with conductive components (such as carbon fibers) cannot be
effectively cured using rf radiation. These materials are thermally cured. Recent machines
which combine both thermally heated metal dies and rf heating after exiting the die have
proven to give much better performance than either of the methods alone.

Parts must be quite hard

(essentially cured) when they
exit the die so that they will
not be deformed by the
pulling mechanism, although
some curing after exiting the
die is possible if done before
the pullers. Post-die curing
can be done with a tunnel
heater, although this adds
considerable length to the line and is notoriously inefficient in heat use. Another method of
post die curing is to use heated, moving C-shaped dies (also called split dies) that have
cavities in the shape of the finished part and close on the part as it exists the die. These dies

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are mounted on a moving belt or chain and stay in contact with the part long enough to
insure that sufficient cure is achieved to withstand the forces of the puller. Off-line curing
could then be used, as required.

The following are some considerations, which need to be taken into account when
purchasing primary dies:

Material selection

The die material should be capable of withstanding continual heating and cooling without
deformation. Usually this means high-grade tool steel. The material should be capable of
resisting wear from abrasion, and be damage tolerant for repeated assembly and
disassembly. The material should be capable of receiving chrome plating of 0.001-0.002
inches (0.025-0.0508 mm) of thickness for wear resistance. Two widely used steels for die
manufacture are A-2 hardened to 55-60 Rockwell hardness and P-20 prehardened to 28-30
Rockwell hardness.

Shrinkage Factors

It is the nature of most resins to shrink after reaching peak exotherm, and during the cooling
process. Because of this a shrinkage factor must be calculated into the die design. This will
enable the die to form the part to the proper dimensions after the part is completely
cooled. A shrinkage factor cannot be unilaterally determined, as each resin system and
reinforcement lay-up is different, however recommended shrinkage factors are:

Thickness dimensions: 1% shrinkage

All other dimensions 0.3% shrinkage

Die Opening Design

The die opening design must accommodate the smooth entry of reinforcements into the
proper position. Generally a symmetrically shaped die is made to utilize either end of the die
as entry or exit, if possible.This enables longer die life between re-chroming. At the opening
of a die a minimum radius of 0.250 inches should be used. The die inlet is tapered at 7–100,
with well rounded edges to prevent fiber fracture.

One Piece or Split Cavity Dies

The advantage of a one-piece die is that the finished part will not have a parting line.A one-
piece gun barrel drilled die is usually less expensive to manufacture, however it may be
more expensive in the long run. If a part seizes up inside a one-piece die during processing,
the die may be impossible to repair.

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Multiple piece dies have the advantage of being easily opened to allow cleaning and
maintenance, however care needs to be given in designing the die so the parting line
between the mold halves does not cause a problem with the part being molded.

Die Surface Treatments

Due to the abrasive nature of fiberglass reinforcements, a protective surface treatment is

required on the die cavity. The most commonly used treatment is hard chrome plating at
0.001-.002 inches (25-50 microns) thick. For dies expected to perform in long term service,
nitriding may be considered.

Die Maintenance

Die maintenance is one of the most important factors in extending die life. Opening the die
after each production run and recording the number of feet of production and the wear
conditions is important.Testing the die surface with copper sulfate for wear spots is
critical.The sooner die wear can be detected and treated the longer the die will last before
major rework.The best time to perform die inspection and maintenance is just after the die
has been pulled from production, prior to being stored. Inspection just prior to installation is
not recommended, as production pressures may make repairs, if needed, difficult, shorting
the life of the die and potentially compromising part quality. Acidic mold release agents are
often used to ease the separation of the part from the metal die. Steel dies exposed to
acidic conditions must be cleaned thoroughly between uses to maximize the lifetime of the
die.

Puller Clamp System

The pultruded product is cooled prior to the traction unit, which can be a counter rotating
caterpillar unit, or preferably, a hand-over-hand reciprocating clamp type unit, since the
caterpillar unit requires the tracks to be fitted with machined rubber pads to accommodate
each pultruded profile. The hand-over-hand unit grips above and below and while one unit
is pulling, the other unit returns to position, ready to take over the role of pulling. Typical
line speeds vary in the range 1.5–100 mh-
1
, depending on the section(s) being
produced. The pulling forces depend on
the type of machine which are available
upwards to some 30 MT.

There are two common puller systems

1. Caterpillar belt

2. Reciprocating clamp puller

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In both systems, pads, typically made of

urethane, must be shaped to match the part
profile in order to apply a uniform clamp
load, which will not cause damage to the
pulled part. The advantage of the caterpillar
belt system is the capacity to provide large
pulling force, spread over a larger part
surface area. The advantage of the
reciprocating clamp puller system is cost, as
it requires only 2 puller pads per clamp vs
10-100 depending on the caterpillar belt
size.

Cut off Saws

Most pultruders utilize what are known as flying
cut off saws. A flying cut off saw moves at the
same speed as the moving part, so the cut edge
of the part is square and straight. Using a non-
flying saw results in cut edges that are not square
and straight. Flying cut off saws are
recommended for part quality. There are two
basic types of flying cut-off saws:

1. Wet saw – A wet saw uses water during the

cutting cycle to cool and lubricate the blade and flush the fiberglass particulate to a filter.
This effectively eliminates dust and airborne particulate.

2. Dry saw – A dry-cut saw uses a continuous rim diamond blade that does not require any
fluid during the cutting cycle, but which gives a good clean cut. A dry-cut saw requires a dust
collection system to capture the fiberglass dust, both to address operator health and
comfort and from a housekeeping standpoint. Using a dry-cut saw without a properly
designed dust collection system is not recommended, due to the dust generated during
cutting, both from an operator health/comfort and a housekeeping standpoint. In most
cases pultruders will utilize an automatic cut-off saw, which automatically cuts the part into
the proper lengths. This enables employees to carry out other duties in order to enhance
productivity.

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Basic Processing Steps

The basic pultrusion process can be divided into the following operations:

1. Reinforcement handling

A suitable creel positions the requisite number of tows, with minimal damage, prior to entry
into the resin bath. If tows are supplied from containers, a christmas tree with ceramic
eyelets will be required to direct the tows to the resin bath. In some pultruded sections,
smaller tows are used in parts where the profile shape does not permit the use of larger
tows. Higher size contents (2–5% w/w) will permit easier handling and minimize fiber
damage. Tows can be joined by knotting, but knots must be staggered to ease their passage
through the die. Hybrid constructions can be used (e.g. with glass and aramid) and
transverse properties can be introduced with an In-feed system using woven cloth, knitted
fabrics, braid, or mat

2. Resin impregnation

The dimensions of resin baths are restricted to minimize the volume of catalyzed resin and
can be heated to control the resin viscosity to promote fiber wetting, although this will
reduce the working life of the bath. To facilitate lacing up, the roller assembly in the resin
bath is manufactured in two parts—a lower fixed set of rollers submerged in the resin bath
and a moveable upper set, under which the fiber is positioned. The assembly is then pressed
down to push the fiber into the bath to contact with the lower set of rollers. This system
facilitates an easy lace-up procedure and ensures good compaction to expel all air and
promote fiber wetting. Alternatively, the fiber can be passed over a drum upon which the
correct amount of resin has been metered and adjusted by a doctor blade.

3. Pre-die forming

A preforming die gently shapes the material and removes all but about 10% of the excess
resin prior to entry into the pultrusion die.

4. Heated die to shape and cure the resin

The pultrusion die can be made from polished chromium plated tool steels, or when
pultruding epoxies, a high chromium content tool steel. The die must be accurately lined up
and its length typically 300–1000 mm, which is governed by the size of the section being
pulled, the pulling speed and the resin system. Longer dies require greater pulling forces
due to the increased frictional drag and a die lubricant, such as zinc stearate, can be added
to the resin mix to help reduce frictional resistance, but which may interfere with any
subsequent composite bonding process. The die inlet is tapered at 7–100, with well rounded
edges to prevent fiber fracture. The excess resin exudes from the inlet end of the die,

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 Pultrusion Process

causing the entering fiber bundle to swell, eventually attaining equilibrium with the process
conditions. Adding this exuded resin to the resin bath will curtail the life of the bath.

Cartridge or plate heaters are preferred for heating the die to a uniform temperature within
±10C and maintaining a temperature gradient along the die to avoid premature gelation,
while taking into account any exotherm. An RF (Radio Frequency wave generator) unit can
be used to either heat the fiber entering the die or the die/resin. The die must be preheated
prior to commencement of pultrusion.

Shrinkage during polymerization reduces die forces and should always be arranged to be
greater than the thermal expansion caused by the temperature rise.

5. Pulling unit to provide traction

The pultruded product is cooled prior to the traction unit, which can be a counter rotating
caterpillar unit, or preferably, a hand-over-hand reciprocating clamp type unit, since the
caterpillar unit requires the tracks to be fitted with machined rubber pads to accommodate
each pultruded profile. The hand-over-hand unit grips above and below and while one unit
is pulling, the other unit returns to position, ready to take over the role of pulling. Typical
line speeds vary in the range 1.5–100 mh_1, depending on the section(s) being produced.
The pulling forces depend on the type of machine which are available upwards to some 30
MT.

6. Cut off saw

Once the pultruded section has left the die and cooled sufficiently, it is clamped and a flying
saw moves along with the clamped section to cut off required lengths. Extra long lengths
can be accommodated by feeding the pultrusion out through a door, window or hatch at the
end of the building.

7. Post cure oven

For optimum properties, all pultruded sections will require post curing and care must be
taken to ensure adequate support along the entire pultruded length to prevent deformation
occurring in the post cure oven.

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Following are some of the considerations while manufacturing and designing

pultruded parts.
Wall Thickness

Wherever possible, select uniform thickness in the cross-section because it provides uniform cooling
and curing, and thus avoids the potential of residual stress and distortions in the part. Moreover,
uniform thickness will provide uniform shrinkage in the part and thus will limit the warpage in the
product. Typically, 2 to 3% shrinkage occurs in the pultruded part. Also, maintain symmetry in the
cross section for minimal distortion. For high-volume production, the thickness of the part is critical
because the curing time and therefore the rate of pull depend on the thickness of the part. For
example, a 0.75-in. thick cross-section can be produced at a rate of approximately 9 in./min,
whereas a 0.125-in. thick cross-section can provide a production rate of 3 to 4 ft/min. Therefore, if a
design requires high rigidity in the part, then it can be achieved by creating deeper sections with
thinner wall or by including ribs in the cross-section. Similarly, if there is a choice between selecting
a thick rod or tube, select the tube because it offers a higher production rate, lower cost, and higher
specific strength.

Corner Design

In a pultruded part, avoid sharp corners and provide generous radii at those corners. Generous radii
offer better material flow at corners as well as improve the strength by distributing stress uniformly
around the corner. A minimum of 0.0625-in. radius is recommended at corners. Another important
consideration in the design of corners is to maintain uniform thickness around the corner. This will
avoid the build-up of resin rich areas, which can crack or flake off during use. Moreover, uniform
thickness will provide uniformity in fiber volume fraction and thus will help in obtaining consistent
part properties.

Tolerances, Flatness, and Straightness

Dimensional tolerances, flatness, and straightness obtained in pultruded parts should be discussed
with the supplier. Standard tolerances on fibreglass pultruded profiles have been established by
industry and ASTM committees. Refer to ASTM 3647-78, ASTM D 3917-80, and ASTM D 3918-80 for
standard specifications on dimensional tolerances and definitions of various terms relating to
pultruded products. Pultrusion is a low-pressure process and therefore does not offer tight
tolerances in the part. Shrinkage is another contributing factor that affects tolerances, flatness, and
straightness. The cost of a product is significantly affected by tolerance requirements. Tight
tolerance implies higher product cost. Therefore, whenever possible, provide generous tolerances
on the part as long as the functionality of the product is not affected.

Surface Texture

Pultrusion is a low-pressure process and typically provides a fiber-rich surface. This can cause
pattern-through of reinforcing materials or fibers getting easily exposed under wear or weathering
conditions. Surfacing veils or finer fiber mats are used as an outer layer to minimize this problem. To
create good UV and outdoor exposure resistance, a 0.001- to 0.0015-in. thick layer of polyurethane
coating is applied as a secondary operation.

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Advantages of using pultrusion

Pultrusion has a number of benefits over other composite processing systems. Some of the
lowest cost, highest quality composite profiles are created by this process. This is because it
is automated and has very little manual interface. A manufacturer can be assured the 1st
ten-meters of pultrusion will have the same quality and consistency as the 100th ten-meters
of pultrusion. Human interface is eliminated, as required in most other processes, such as
molding and hand-lay-up. Quality is not a function of motivation of factory technicians.

Another distinct advantage of the pultrusion process is cost. It is not unusual to find 80-90%
of the cost of pultrusion profiles are the raw material costs. The amortized machine costs
and the labor to run pultrusion machines is a small portion of the total factory costs. This
has been a primary driver for pultrusion being one of the fastest growing and accepted
manufacturing processes in the composites industry.

Features Description Benefits Applications

Unit strength in tension & Optional strength as Structural process

compression is approx. 20
Strong x that of steel when these
properties are combined
on the basis of unit
density
desired. Exceptionally equipment support.
high impact strength Tank supports. Cooling
reduces damage tower ancillaries.
potential Flooring supports.
Trusses & joints.

Density of pultruded
Light Weight components is about 20%
of steel and 60% of
aluminium
Higher performance at
less weight. Lower Automotive leaf springs
shipping, handling & & bumpers.
installation costs. Less Prefabricated walkways
operational energy & platforms. Bus
demand. components.

Corrosion Chemical plant hand

Resistant Unaffected by exposure to Minimum maintenance railings, gratings,
a great variety of corrosive costs. Long term safety. walkways & bridges.
environment & chemicals. Longer life. Cable trays. Pipe
supports.
Lesser no. of
Electrical components. Non-
Insulation Provides strength & magnetic & safe. Ladders, Cable trays.
rigidity with dielectric Predictable insulation Switch gear
properties. values for wide range components. Mounting
of frequencies. braces and backboards.

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Pultruded components
have a low thermal
Thermal conductivity, 1/250 of
Insulation aluminium & 1/60 of steel.
Many individual
Consolida- components can be
tion combined into a large
profile.
Pultruded components are
Dimensional highly resistant to warping
Stability stretch/swelling over a
wide range of
temperature & stresses.
The pultruded
Safety components are very
strong & safe to work
with. They are microbes
and insect proof.
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Department of Mechanical and Manufacturing
Pultrusion Process
Reduces installation Bulk head frames. Walk
thickness. Eliminates in refrigerator door
condensation jams. Window frames.
problems. Reduces Insulated roll up panel
energy operation doors.
requirements.
Reduced assembly cost. Window latch supports.
Reduced inventory. Roll up door
Fewer parts improve
reliability.
No permanent Spring bumpers.
deformation under high Crossing gate arms.
stress. Close Scrubber components.
tolerances.
Many gratings suffer This property makes
from the problem of them ideal choice for
microbes etc. due to pharmaceutical & food
wet or unhygienic industries.
working conditions.
22
 Pultrusion Process

DISADVANTAGES OF PULTRUSION
1. It is suitable for parts that have constant cross-sections along their length. Tapered and
complex shapes cannot be produced.

2. Very high-tolerance parts on the inside and outside dimensions cannot be produced using
the pultrusion process.

3. Thin wall parts cannot be produced.

4. Fiber angles on pultruded parts are limited to 0°. Fabrics are used to get bidirectional
properties.

5. Structures requiring complex loading cannot be produced using this process because the
properties are mostly limited to the axial direction.

6. Voids may result in parts if excessive opening given at die entrance

7. Standards play an important role in acceptance of new materials. The lack of design
standards is a significant constraint to the use and growth of composites in structural
applications.

8. Shrinkage (commonly 2% - 3%)

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References
Pultrusion of Glass Fiber Composites - A Technical Manual (Owens Corning)

PULTRUSION — HIGH PRODUCTIVITY NOW, GETTING EVEN BETTER, By A. Brent

Strong/Brigham Young University

Manufacture by Pultrusion - Dr J M Methven, MACE

Pultrusion of Composites - An Overview, Atul Mittal & Soumitra Biswas

Carbon Fibers and Their Composites - Peter Morgan

COMPOSITES MANUFACTURING - Materials, Product, and Process Engineering,

Sanjay.K.Mazumdar, Ph.D.

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