Carbon layer thickness: do you know it?


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AlessandroPA
AlessandroPA
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Hi guys, I hope somebody can help me.
I have to make a 27,2mm diameter tube, and to make this I'will wrap more times a single sheet of carbon around a 1" diameter tube (25,4mm). 
the tube will be used to be connected to the hull of a saddle I'm going to create.
My question is: does anybody know the thickness of a single layer of carbon?
In this way I will know the number of wrapping I have to do in order to reach the 27,2mm.
Consider that, after the wrapping, the created tube will be closed into the bag and used with the vacuum bagging, so that the carbon will be more compressed.
In the end I will give a layer of glossy finishing.

Thanks a lot for the help Wink
Hanaldo
Hanaldo
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Depends on the weight of fabric you are using. If you're using regular 200g fabric, then each layer is approximately 0.25mm when consolidated under vacuum. 

How accurate do you actually need to be? I think you might struggle to get it to exactly 27.2mm, especially if you are using wet lay. 
Edited 10 Years Ago by Hanaldo
AlessandroPA
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Well, I will try to make a 27,2mm but considering the finishing, even just a bit less should be ok.
I use 200gr Plain fabric so, if you say its final thickness is 0,25mm I should wrap 7 layers.
That's why 27,2mm - 25,4mm = 1,8mm (thickness of the carbon tube I have to make) So 0,25 x 7=1,75mm that should be good enough
I will let you know, thanks Wink

Hanaldo (24/04/2015)
Depends on the weight of fabric you are using. If you're using regular 200g fabric, then each layer is approximately 0.25mm when consolidated under vacuum. 

How accurate do you actually need to be? I think you might struggle to get it to exactly 27.2mm, especially if you are using wet lay. 

Hanaldo
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That is assuming a good resin ratio though. Are you doing it wet lay? It's a bit harder to judge the thickness with wet lay because it's harder to hit your required resin/fabric ratio. Pre-preg or infusion you can nail a 60/40 ratio and get very accurate thicknesses. Wet lay you are probably looking at a 50/50 ratio if you measure correctly and can get the lay up right, so it could end up a bit thicker. 

You've got a touch of leeway there with your 7 layers though, so you will probably still be ok. Just something to keep in mind. 
redeye
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If the outer diameter is important, then why not look at making a female mould out of some pipe in 2 halves with bolted together flanges and using an inflatable bladder on the internal diameter. You'd have to "make" a pipe with the correct internal diameter though but it would give you good surface finish and a more accurate dimension. Bare in mind I haven't done this before but I'm sure the experts will chime in.Good luck regardless of your approach. 
AlessandroPA
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That's ok, so I will use the ratio 50/50, even considering that into the bag, the layers of peelply and other fabrics will absorb the resin in excess.

Then, I will check the diameter before to apply the final layer of finishing, maybe I won't need of it if the diameter is good enough Wink

Hanaldo (25/04/2015)
That is assuming a good resin ratio though. Are you doing it wet lay? It's a bit harder to judge the thickness with wet lay because it's harder to hit your required resin/fabric ratio. Pre-preg or infusion you can nail a 60/40 ratio and get very accurate thicknesses. Wet lay you are probably looking at a 50/50 ratio if you measure correctly and can get the lay up right, so it could end up a bit thicker. 



You've got a touch of leeway there with your 7 layers though, so you will probably still be ok. Just something to keep in mind. 

AlessandroPA
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I tried to make this but it is quite difficult, I made only one of the two pieces.
It should be ok if the mould would be in aluminium or steel CNC (really expensive) so that the two halves match perfectly using bolts on the flanges, but I can do moulds in general with fiberglass and gelcoat and is really hard to connect the halves.
Anyway thanks for your tip, I will let you know RolleyesWink

redeye (25/04/2015)
If the outer diameter is important, then why not look at making a female mould out of some pipe in 2 halves with bolted together flanges and using an inflatable bladder on the internal diameter. You'd have to "make" a pipe with the correct internal diameter though but it would give you good surface finish and a more accurate dimension. Bare in mind I haven't done this before but I'm sure the experts will chime in.Good luck regardless of your approach. 

Hanaldo
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You need to put keys on the flange to lock the pieces together. 
Warren (Staff)
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If you are in effect, "roll wrapping" the fibre, albeit wet lay rather than pre-preg, you can use a Composites High Shrink Tape to consolidate the layers and squeeze out the excess resin.

It will also have the benefit of leaving a relatively smooth even outer finish with just small "ribs" from the tape edges that can be sanded out.


Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
AlessandroPA
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Ok, thanks. I would try later this technique Wink
Hanaldo (25/04/2015)
You need to put keys on the flange to lock the pieces together. 

GO

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