*2.1.2. Quickstep composites*

Quickstep is an Australian-listed company. The Quickstep process forms composite parts using 4 psi (low pressure) on a rigid tool suspended between two elastomeric membranes back filled with glycol fluid. Their large format out of autoclave forming and curing process works well for large parts. Aerospace parts such as wing skins can be molded using either prepreg materials or resin injection molding [12, 13].

has a thermal conductivity that is 24 times greater than that of air and that circulating water increases this effectiveness even further by a factor of 10. Our objective is to study the viability

Out of Autoclave Metal and FRP Composites Thermo-Hydroforming

http://dx.doi.org/10.5772/intechopen.81600

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Hydroforming has a well-documented history of safely forming sheet metal materials at pressures of up to 20,000 psi (137.89 Mpa) well beyond the requirements of composite materials. Because hydroforming machines can deliver and contain high fluid pressure, it is believed that the addition of a thermal cycle to heat & cool the forming chamber's working fluid will enable a significant industrial advancement in sheet hydroforming machines. The new methodology will allow for a single machine to shape, catalyze and cure prepreg composite materials, thermal plastics and matrix materials in addition to its traditional use as a metal forming machine. With FEA simulations demonstrated, qualitative assessments can be made to facilitate the future validity for development, implementation and commercialization of thermo-hydro-

Fresh water has a very high level of thermal conductance. It is 100% better than glycerol and 350% better than machine oil. However, in order to be used at high temperature water must be pressurized to prevent boiling. In this design configuration pressure is applied as a part of the process. As a result, at 300 psi water can be used at temperatures of approximately 400°F (**Figures 2** and **3**).

The first load step consists of a linear static analysis where only the pressure load is applied. This allows for the composites to be in contact with the tool. Following this, a transient coupled thermal displacement step is run to obtain the temperature distribution and heat flux

of adopting these methodologies to hydroforming.

**3. Fluid properties for thermal-hydroforming**

**4. FEA simulation: thermal-hydroforming of composites**

forming machinery.

**4.1. Analysis type and geometry**

through time. Total time used was 200 s.

**Figure 2.** Thermal expansion of select materials.
