I N TR O D U C TI O N

Composites are fibrous materials infused with a tough and durable plastic.
Composite material is a technology that is being used to make many items in
todays world stronger and lighter. These materials are starting to be
incorporated into the armor of combat vehicles and soldiers. When these
panels are made in the most economical way, they are inferior to those that
take much more time and money to construct. Developing a method that is
fast and reliable is critical. A controlled setup must be designed in order to
get optimized infusion. The experimental process in which infusion is
accomplished is called Vacuum Assisted Resin Infusion Molding (VARIM).
In this process a vacuum pulls resin in from a feed tube to distribute it
evenly into the preform.
Vacuum-assisted resin infusion molding (VARIM) has become a very
attractive fabrication technology in recent years because of its low-cost
tooling and its scalability to very large structures. It minimizes the void
contents inside the molded composites, reduces VOC emissions and results
in less scrap than other molding techniques. VARIM has been used
primarily with resin systems that cure at room temperature, such as vinyl
ester and epoxies. High-temperature polymer matrix composites for highperformance applications that require cure at high temperature are currently
produced by this technique. This process is cost effective and is applicable to
small-size as well as large-size structures. The potentials of VARIM for
fabricating high-temperature polymer composite structures with properties

and quality that match those of the autoclave/prepreg molded ones are
widely unexplored.
To define Vacuum Assist Resin Infusion Molding the process is briefly
described as :-

Fiber reinforcement is placed in a mold. Then the vacuum is applied

on the reinforcement against the mold. After this the mold is heated. The resin
is then injected into the reinforcement. The motive force in VARIM is
pressure. Therefore vacuum applied on the mold and the reinforcement acts as

the motive force, and the pressure in the mold cavity is lower than atmospheric
pressure.

The Vacuum Assist Resin Infusion Molding (VARIM) is a vacuum-assisted

resin transfer molding process that produces parts excellent for marine,
aerospace, transportation, and infrastructure applications. The process is a
proven method of producing high-quality composite parts made from a wide
range of fiber and resin combinations. All commercial fibers, core materials,
and any resin in the range of 50 centipoise to 1000 centipoise will VARIM
with outstanding results. The process can be run at room or elevated
temperatures. VARIM can produce large (2,000 sq. ft.) parts, using both
single skin and cored construction, and highly complex three-dimensional
trussed parts weighing up to 3,000 lbs. The resulting composite material
properties directly compare to properties that had only been achievable in
highly controlled expensive autoclave processes.
When considering molding options for composites production,
there are several possibilities. In the case of high volume production, the
compression molding process produces low cost parts, but requires a high
capital investment in presses, infrastructure and tooling and maintenance also.
At the other end of the spectrum, infusion molding requires very low capital
investment, but produces cycle times similar or slower than traditional open
molding. Vacuum Assist Resin Infusion Molding (VARIM) stands in the gap able to produce mid-range volumes of parts at a moderate capital investment.

A closed form solution for the flow of resin in the vacuum-assisted

resin infusion molding (VARIM) process is used extensively for affordable
manufacturing of large composite structures. During VARIM processing, a
highly permeable distribution medium is incorporated into the preform as a
surface layer. During infusion, the resin flows preferentially across the
surface, simultaneously through the preform, to a complex flow front. The
analytical solution presented here provides insight into the scaling laws
governing fill times and resin inlet placement as a function of the properties
of the preform, distribution media, and resin. The formulation assumes that
the flow is fully developed and is divided into two areas: (1) a saturated
region with no cross flow, and (2) a flow front region, which moves with a
uniform velocity, where the resin is infiltrating into the preform from the
distribution medium.

The VARIM process is inherently repeatable. Once equilibrium resin

content is achieved (55% to 60% fiber volume, depending on fabric
architecture), the process stops. Aerospace grade quality is ensured by first
eliminating all air voids before the resin is infused, enabling the fabric preform to act as an effective breather layer. As the resin is infused, it travels in
controlled waves that work to completely wet out the reinforcing fibers and
eliminate any voids that could be created by the volatile organic compounds
(VOCs) emitted by the resin during the cure cycle. The process has been
used to infuse laminates up to 6 inches thick with the same high-quality
results as a simple 1/8 inch laminate.

Some areas of application of VARIM are marine, aerospace, transportation,

wind turbine blades and infrastructure applications :-

R A W M A TER I A LS
A) REINFORCEMENT MATERIALS:
Following material & material forms are normally used for the VARIM
process:
Forms of E glass type fibre glass reinforcements:
VARIM grade chopped strand mat
Needled mat
Woven roving
Woven cloth
UD reinforcements/continuous rovings
UD-CSM

combination

(Stitched/needled/powder

bonded

mat

configurations)
Texturised rovings
Continuous strand mat
Stitched mat
Carbon / Kevlar / Fibreglass hybrid reinforcements in the form of :
Woven roving
Woven cloth
UD CSM form

Surface veils (to improve surface finish)

Fibreglass surface mat
Polyester veil fabric-woven
Polyester non-woven fabrics

Glass fibre

B) RESINS
Polyester resins - GP/Isophthalic/Vinyl ester/Bisphenolc
Epoxy resins
Phenolic resins and other thermoset resins

C) FILTERS & ADDITIVES

Low profile additives, internal release agents (used in case of hot
moulds), Lubricants, viscosity modifiers or surface tension relievers/
UV Stabilizers, etc.

Powder, calcium carbonate, Quartz powder, Alumina - Trihydrate,

Titanium dioxide, Fine silica, etc. (added for requirements of cost
reduction / insulation / part surface quality / to reduce shrinkage /
flame retardancy, etc.)
Pigment pastes - Polyester/Epoxy/Pigments of various colours,
shades.

D) AUXILLARY MATERIALS
Mould release films (Wax & PVA) & coatings, Semi permanent release
agents, permanent coatings (like PTFE/Silicone rubbers, etc.).

MOLD AND MACHINE

P A R TS
Aluminum-FRP Mould
Vacuum Pumps
Small Parts Mould
Resin and Mixing Machine
Sawing and Drilling Machine
Painting Cabins
Heating Coils/Piping Systems
Temperature Measuring System
Guide pins, release pins, air release channels

V A R I M P R O C ES S
STEP 1
Cleaning of Mould and application of releasing agent.

STEP 2
To adhere Peel ply on Mould, Double-sided Tape is used.

STEP 3
Then, glass fabric layers are laid according to the design. CSM is
laid on edge throughout the Mould.

STEP 4
Balsa, Foam and other supporting materials are laid on the
mould

STEP 5
Rubber profile is put on the edges of the mould for the easy flow
of the resin.

STEP 6
Then put Peel Ply on the fabrics.

STEP 7
Then put Perforated Sieve.

10

STEP 8
Then lay Distribution Net according to the design.

STEP 9
Then we place Spiral Tube and Injection T for the transportation
of resin in the glass fabric.

STEP 10
After that the Absorbent material is placed along the Flange over
Vacuum points.

STEP11
Tissue Paper is put across the Mould between 2 successive Vacuum
points all along the Mould.

STEP12
Then Tacky Tape is placed outside the Vacuum point all along the
Flange to have a Vacuum plastic over the Mould. This is referred as
inside Vacuum. Outside, another Vacuum plastic is placed to
protect the inner one.

STEP13
Inner Vacuum is applied with the help of Vacuum pump to maintain
a certain pressure. A little tolerance in drop of Vacuum is allowed
for a certain period of time.

STEP14
Similarly a little tolerance of pressure is allowed for fixed time in outer
Vacuum Plastic.

11

STEP15
Now we apply Epoxy Resin system (Resin + Hardener) using 100:32
each by proportion.

STEP16
Once the infusion is completed , Vacuum is dropped to a certain
value fixed by the designer.

STEP17
Then the mould is heated first for two hours. Once the Exotherm
is completed heating is provided for a period of 4 hours and the
temp is gradually raised for cure to complete.

STEP20
After cooling for certain hours, the Product is released with the help
of clamps.

12

DIAGRAM OF PROCESS

Figure showing Vacuum Assist Resin Infusion Molding

13

ADVANTAGES OF VARIM
The inherent economic and environmental advantages of a vacuum-assisted
resin infusion molding (VARIM) composite manufacturing process have
caused an increase in the number of applications and generated research
activity within the industry. Some of them are :-

It can be used with most resin systems (polyester, vinylester and

epoxy).

It can also be used with most woven, stitched, knitted, braided or

random fabrics.

It has relatively low tooling costs for high-performance components.

The process uses the injection of resin in combination with a vacuum

and captured under a bag to thoroughly impregnate the fiber
reinforcement. Thus resin fully wets the fibres, making it more strong
and free of dry patches to produce large structural shapes that are
virtually void-free.

This technique produces parts with higher fibre content than any other
process. Higher fibre volume fraction gives improved mechanical
performance.

14

Parts produced using this method is stronger, lighter, and cheaper to

produce.

Furthermore, the process is very environmentally friendly. Volatile

Organic Compounds (VOCs) and Hazardous Air Pollutants (HAPs)
are drastically reduced. This also means that the working environment
is greatly improved.

VIP also allows unlimited setup time because the resin is not
catalyzed until all the materials are in place.

The vacuum bag evenly applies pressure, conforming to both simple

and complex shapes.

Application of vacuum provides control of part thickness by

compressing the laminate during cure.

Application of vacuum removes air, excess resin and volatiles

resulting in a good uniform product.

15

A P P LI C A TI O N S
The Vacuum Assist Resin Infusion Molding (VARIM) is a vacuum-assisted
resin transfer molding process that produces parts excellent for marine,
aerospace, transportation, and infrastructure applications. The process is a
proven method of producing high-quality composite parts made from a wide
range of fiber and resin combinations. Some of the areas of application are
discussed here.

Transportation
Businesses involved in the transportation of goods and services are
continually looking for ways to reduce costs and stay competitive. Whether
its people or goods, the cost to move a pound of weight, continues to rise.
This is primarily driven by high-energy costs and by the type of vehicle and
materials used to produce that vehicle. For some, reducing costs may mean
improving fuel mileage or lowering maintenance costs while others are
looking for higher capacity or lower operating expenses.

Railway Coaches

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Military Applications
The military forces are designed to respond immediately to deployment and
other reactive situations. Soldiers, supplies and vehicles must be prepared
for any challenge in a moments notice. Heavy vehicles hinder rapid
deployment and put military personnel at risk. VARIM technology addresses
these problems with composite solutions that ensure battle readiness and
increase personnel protection. The main objective is optimizing vehicles for
all war situations through lightweight, durable composite solutions.
VARIM focus on delivering composite solutions for military applicatins
that:

Significantly reduce weight

Increase vehicle durability
Allow for the integration of other important features, like personnel
protection
Eliminate corrosion
Save the military millions of dollars over the vehicle's life cycle

17

VARIM has produced composite materials to address many challenges in

the military. In addition to actively developing composite components for
the Army's tactical wheeled vehicles, VARIM is developing an all
composite cab armored for complete personnel protection, and will be
working on developing a next generation, lightweight all composite vehicle
for the Army.

Wind energy
The VARIM process is effectively used in designing and building large scale
wind turbine blades. Since the process is vacuum assisted, the problem of
dry patches is not there as in other techniques where the fibere is not fully
wetted by the resin. As the blade has to suffer various extreme
environmental conditions, it has to be free from points of failures like dry
patches, white patches etc which can only be achieved by this process.

18

Other Applications
Marine
Aerospace
Automobiles
Large Structural Components
Civil Infrastructure

19

WITH THE APPLICATION OF THE VACUUM ASSIST

RESIN INFUSION MOULDING WE ARE GOING TO
DESIGN A PRODUCT WHICH IS --BLADE OF WIND ENERGY CONVERTER.

Finished blade

20

W I N D EN ER G Y
CONVERTERS
Wind is simply air in motion and the energy produced by this moving air is
called wind energy. The unequal heating of land and water by sun is the
main cause of wind generation on the earths surface. Wind is one of the
vital renewable sources of energy. Windmills are technically known as wind
energy converters (WECs). WECs are the machines used for the
production of electricity. These machines use wind as the source of energy.
WECs are producing energy without any pollution. The sound produced by
these WECs is about 40 db, which is not harmful to human ears and comes
in the favorable region.

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MAIN PARTS OF ROTOR

B LA D E
PREFORM

Its a partially cured layer of Glass Fibres made to give strength & enough
thickness at root section

SPARBOOM

Its a Glass Reinforced component made by Resin Infusion to give bending

strength to the blade as Backbone

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LEADING EDGE GLUE CAP

Its a Glass Reinforced component made by Resin Infusion to form the cap
like structure between the Pressure and suction Shell of the blade.

TRAILING EDGE GLUE CAP

Its a Glass Reinforced component made by Resin Infusion form a cap like
structure at rear part of blade

23

Web

Its a Glass Reinforced ,PVC foam / Balsa sandwiched component made by

Resin Infusion, gives support to Suction and Pressure shell from innerside

SPOILER

Its a Glass Reinforced ,PVC foam / Balsa sandwiched component made

separately by Resin Infusion and is mounted on root side of blade to
increase the overall output of Turbine between the Pressure and suction
Shell of the blade.

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O U TLI N E O F TH E M A I N
P R O C ES S
1.Blank Blade making.
a) Preform making.
b) Sparboom making.
c) Web making.
d) T/E & L/E Glue Caps making.
e) Spoiler making.
f) Spoiler Web.
g) Spoiler Glue Cap.
h) Balancing chamber.
i) Shell Making.
j) Shell Joining and Releasing.
2. Deburring Process.
3. Sawing and Drilling Process.
4. Spoiler Fixing Process.
5. Finishing Process.
6. Dispatch.

25

BLANK BLADE MAKING

P R O C ES S
PREFORM MAKING
MATERIALS USED
a) Glass Fiber (G-2/1/0/1-1169 powder coated).
b) CSM (width of 300/100/250/200 mm used respectively).

PROCESS
STEP 1
Clean the Mould. (Once in 15 days) with the use of Acmosion.
STEP 2
Put G1 + G1 strips offset to radial direction along the Mould.
STEP 3
Table cutting of Layers (50 pieces) and lay them in the Mould
according to the design.
STEP 4
Press (iron) out each layer straighten it and hold the layers at their
desired positions.

26

STEP 5
Apply Vacuum of 1 bar of 60 0 C for 1 hour.
STEP 6
Remove Vacuum gradually by switching off the Vacuum pump.
STEP 7
Switch off the heater and use for Shell making.

27

SPARBOOM MAKING
MATERIALS USED
a) Double-sided Tape
b) Peel ply
c) CSM of width 50 mm
d) The Glass Fiber used is R-1/0-1188-M70
e) Balsa and Foam
f) Perforated Sieve
g) Spiral Tube and T
h) Tissue Paper
i) Tacky Tape
j) Rubber Profile (15 x 16 , 15 x 10 )
k) Distribution Net.
l) Epoxy Resin System

PROCESS
There are two Moulds for Sparboom.
A. Suction and
B. Pressure
Same layout is used for the both kinds of Mould.
STEP 1
Cleaning of Suction Mould by using NC-55.

28

STEP 2
To adhere Peel ply on Mould, Double-sided Tape is used.
STEP 3
Then, R1 layers of 5 nos (width 420 mm) are laid according to the
design. 50 mm CSM is laid on either edge (Leading & trailing)
throughout the Mould.
STEP 4
Balsa and Foam laying on the mould
L/E side :
Foam - 10 mm of width 61mm from R 1800 to R 3300.
Balsa - 9.5 mm of width 61mm from R 3300 to R 19000.
(Chamfer 150 mm at starting and with lay-up 15mm)
T/E side :
Foam 16 mm of width 56mm from R 1800 to R 4300.
(Chamfer 200 mm at starting and with lay-up 35 mm)
Balsa 15.9 mm from R 4300 to R 6000.
Balsa 12.7 mm from R 6000 to R 15000.
Balsa 9.5 mm from R 15000 to R 19000.
Balsa 9.55mm from R 19000 to R 22000
(Chamfer at 19000 , 300mm up to 9.5-0 mm)
(Chamfer at 22000 , 30mm to 5 mm)

STEP 5
Rubber profile use on T/E side :
15x16mm
R 1800 to R 15000
15x10mm
R 15000 to R 22000
G1+G1 layer of 100mm width used to cover foam
T/E side R 1800 to R 4690
L/E side R 1800 to R 4520

29

STEP 6
Rest of 20 layers of R1 is used according to the design.

STEP 7
Put Peel ply from R 1800 to R 22500.

STEP 8
Put Perforated Sieve from R 1800 to R 22500.

STEP 9
Put Distribution Net according to the design.

STEP 10
Place Injection T at R 8000 and 12000.
Place Spiral Tube at R 2800 to R 8000 and R 8000 to R 12000 and
then R 12000 to R 21800.

STEP 11
Place Absorbent material of 30mm is placed along the Flange over
Vacuum points.

STEP 12
Tissue Paper is put across the Mould between 2 successive Vacuum
points all along the Mould.

STEP 13
Tacky Tape is placed outside the Vacuum point all along the Flange
to have a Vacuum plastic over the Mould. This is referred as
inside Vacuum. Outside, another Vacuum plastic is placed to
protect the inner one.

30

STEP 14
Inner Vacuum is applied with the help of Vacuum pump to maintain
a pressure of 1 bar. Tolerance of drop in Vacuum of 30 Milibar is
allowed for 10 Minutes.
STEP 15
Similarly tolerance of 30 Milibar is allowed for 3 Minutes in outer
Vacuum Plastic.

STEP 16
Once the Quality Dept. approves the Vacuum, then a drop till 50
Milibar is done manually by regulation of valve.

STEP 17
Now apply Epoxy Resin system (Resin + Hardener) using 100:32
each by proportion.

RESIN INFUSION PROCESS IN SPARBOOM

31

STEP 18
Once the infusion is completed, Vacuum is dropped to 50 Milibar.
STEP 19
Then the mould is heated to 650 C for two hours. Once the Exotherm
is completed heating is provided for a period of 4 hours and the
temp is gradually raised to 850 C.

STEP 20
After 4 hours, the Sparboom is released when mould temp down up
to 400 - 450 C from the Mould.

32

WEB MAKING
MATERIALS USED
a) The Glass Fiber used is G1+G1
b) Peel ply
c) CSM
d) Double-sided Tape
e) Balsa and Foam
f) Perforated Sieve
g) Spiral Tube and T
h) Vacuum Plastic
i) Tissue Paper
j) Tacky Tape
k) Epoxy Resin System.

PROCESS
Radial position of Web is from R- 2700 to R- 21800.

STEP 1
Cleaning of the Mould with Acmosion.

STEP 2
Placing of double sided tape for Adherence of the subsequent
Peelply.

33

STEP 3
Peel ply is placed along the Flange of the Web as,
Layer 1 R 17000 to R 21800 of 300 mm.
Layer 2 R 2700 to R 17000 of 200 mm.

STEP 4
Place Layer of G1+G1 (4 Nos) throughout the mould.
Layer 1 R 2700 to R 21800
Layer 2 R 2700 to R 20500
Layer 3 R 2700 to R 17000
Layer 4 R 2700 to R 4800.

STEP 5
Balsa & Foam are placed according to design.
Gap between Balsa & Foam is filled with cotton powder.

STEP 6
120 mm layer of G1+G1 is placed on both sides along the Flange of
Web From R 2700 to R 20500.
Another 100mm G1+ G1 layers are placed from R 4800 to R 20500.

STEP 7
CSM is placed all along the above layers.i.e. From R 2700 R 21800.

STEP 8
Spiral Tube is placed 80 100 mm from mould Edge.
T position at R 6000 and another at R 12000 for Resin infusion.
Distribution Net start at R 2700 & End at R 21700.
STEP 9
Then 100 mm CSM is placed all along the Spiral Tube and peelply is then laid at R 2900 to R 21600.

34

STEP 10
Place Absorbent material of 30mm is placed along the Flange over
Vacuum points.
STEP 11
Tissue Paper is put across the Mould between 2 successive
Vacuums point all along the Mould.

STEP 12
Tacky Tape is placed outside the Vacuum point all along the
Flange to have a Vacuum plastic over the Mould. This is
referred as inside Vacuum. Outside, another Vacuum plastic is
placed to protect the inner one.

STEP 13
Inner Vacuum is applied with the help of Vacuum pump to
maintain a pressure of 1 bar. Tolerance of drop in Vacuum of 30
Milibar is allowed for 10 Minutes.

STEP 14
Similarly tolerance of 30 Milibar is allowed for 3 Minutes in outer
Vacuum Plastic.

STEP 15
Once the Quality Dept. approves the Vacuum, then a drop till 95
Milibar is done manually by regulation of valve.

STEP 16
Now apply Epoxy Resin system (Resin + Hardener) using 50%
each by proportion.

35

STEP 17
Once the infusion is completed , Vacuum is dropped to 75 Milibar.
STEP 18
Once the Exotherm is completed heating is provided for a period
of 4 hours and then cooled subsequently.

A HEATED WEB KEPT FOR COOLING

36

LEADING EDGE GLUE CAP

MAKING
MATERIALS USEDa) The Glass Fiber used is R-1/0-1188-M70
b) Peel ply
c) CSM of width 50 mm
d) Double-sided Tape
e) Balsa and Foam
f) G1+G1
g) Perforated Sieve
h) Spiral Tube and T
i) Tissue Paper
j) Tacky Tape
k) Epoxy Resin System

PROCESS
STEP 1
Cleaning of Suction Mould by using NC-55 & Acmosion.

STEP 2
To adhere Peel ply on Mould, Double - sided Tape is used.

STEP 3
Peel ply is placed all along the Mould according to the design
from R1100 to R 24000.

37

STEP 4
Three layer of G1+G1 is placed from
R1100 to R 6500.
R1100 to R 6300.
R1100 to R 6100.

STEP 5
G1+G1 layer 0f 120mm is placed from
R 6200 to R 19600
R 6000 to R 19750
R 5800 to R 17000.

STEP 6
G1+G1 layer of 85mm is placed from
R 19450 to R 24000
R 19650 to R 24000.

STEP 7
Place R1 layer from R 1950 to R 18700 reducing by 150mm from
both the sides 7 layers subsequently.

STEP 8
Pocket of G2 layer is placed from R 1100 to R 3430.
STEP 9
Aluminum flat strip is placed from R 1350 to R 23995.

STEP 10
85mm G1+G1 is placed over the aluminium strip from R 1750 to
R 23745.

38

STEP 11
CSM is placed from R 63oo to R 23745.

STEP 12
Peel ply is placed all along the layer.
STEP 13
Perforated film is placed from R1200 to R 24000.

STEP 14
Sieve is placed from R 1200 to R 6300.

STEP 15
Place insulation paper from R 1200 to R 24000.

STEP 16
Spiral Tube is placed over insulation paper.

STEP 17
Injection T is placed at R 2000 and at R 13000.

STEP 18
Vacuum Plastic is done one over the other.
STEP 19
Tacky Tape is placed outside the Vacuum point all along the
flange to have a Vacuum plastic over the Mould. This is
referred as inside Vacuum. Outside with another Vacuum
plastic is placed to protect the inner one.

39

STEP 20
Inner Vacuum is applied with the help of Vacuum pump to
maintain a pressure of 1 bar. Tolerance of drop in Vacuum of
30 Milibar is allowed for 10 Minutes.
Similarly tolerance of 30 Milibar is allowed for 2 Minutes in outer
Vacuum Plastic.

STEP 21
Once the Quality Dept. approves the Vacuum, then a drop till 97
Milibar is done manually by regulation of valve.
.
STEP 22
Now apply Epoxy Resin system (Resin + Hardener) using 50% each by
Proportion.

STEP 23
Once the infusion is completed Vacuum is dropped to 75 Milibar.

STEP 24
Once the exotherm is completed heating is provided for a
period of 2 hours.

40

TRAILING EDGE GLUE CAP

MAKING
MATERIALS USED
a)

The Glass Fiber used is R-1/0-1188-M70

b)

Peel ply

c)

CSM of width 50 mm

d)

Double sided tape

e)

Balsa and Foam

f)

G2 layer

g)

G1+G1 layer

h)

Perforated sieve

i)

Spiral Tube and T

j)

Tissue paper

k)

Tacky tape

l)

Epoxy Resin System

PROCESS
STEP 1
Cleaning of the Mould with NC-55 & Flange with Acmosion.

STEP 2
Placing of Double-sided Tape for Adherence of the subsequent
Peel ply.

41

STEP 3
Three layer of G1 +G1 is placed from
R 1100 to R 10500
R 1100 to R 10300
R 1100 to R 10100

STEP 4
R1 is placed from R 1950 to R 9200. 16 layer of R1 are placed
one above the other by reducing 75mm from R 1950 and
150mm from R 9200 for every subsequent layer.

STEP 5
Then 48 pocket of G2 is placed from R 1100 to R 3430.

STEP 6
CSM of 70 mm is placed from R 5000 to the end.

STEP 7
Peel ply is placed from R1100 to R 10000.

STEP 8
Perforated plastic is placed over CSM from R 1100 to
R 9000.

STEP 9
70 mm Net is placed from R 1100 to R 5000.

STEP 10
Insulation paper is placed centrally from R 100 to R 9000.

42

STEP 11
Spiral Tube is placed over the insulation paper.

STEP 12
Resin infusion T is placed at R2000 to R 6800.

STEP 13
Place Vacuum flash absorbent all along the Vacuum point.

STEP 14
Inside & outside Vacuum Plastic is placed.
STEP 15
Tissue Paper is placed between two successive Vacuum
points.

STEP 16
Tacky Tape is placed outside the Vacuum point all along the
flange to have a Vacuum plastic over the Mould. This is
referred as inside Vacuum. Outside with another Vacuum
plastic is placed to protect the inner one.

STEP 17
Inner Vacuum is applied with the help of Vacuum pump to
maintain a pressure of 1 bar. Tolerance of drop in Vacuum of
30 Milibar is allowed for 10 Minutes.

STEP 18
Resin system is allowed to infuse all along the layers up to a
period of two hours.

43

SPOILER MAKING
MATERIALS USED
a) Double-sided Tape
b) Peel ply
c) CSM of width 50 mm
d) The Glass Fiber used is R-1/0-1188-M70
e) Balsa and Foam
f) G2 Layer
g) G1+G1
h) Perforated Sieve
i) Spiral Tube and T
j) Tissue Paper
k) Tacky Tape
l) Epoxy Resin system

PROCESS
STEP 1
Cleaning of Suction Mould by using NC-55 & Acmosion.

STEP 2
To adhere Peel ply on Mould, Double-sided Tape is used.

STEP 3
Peel ply is placed over the Mould from R 2200 to R 11500.
44

STEP 4
Leading side G1+G1 100mm is placed from R 2200 to R 11500.

STEP 5
G2 layer is placed from R 2200 to R 11500.

STEP 6
G1 layer of 100 mm is placed from R 2200 to R 11500.
STEP 7
G1 of 80 mm is placed over leading side from R 2200 to
R 11500.

STEP 8
Foam 140 mm and 120 mm are placed above one another
across the Root side of Length 1200mm starting from R 2200.

STEP 9
Balsa of 9.5mm is placed from R 2270 to R 10350 according to the
design.

STEP 10
G1 of 100mm is placed on leading side from R 2200 along
the profile.

STEP 11
G2 layer is placed from R 2200 to R 11500.

STEP 12
Spoiler drilling edge Glue Cap is placed from R 2254 to R 8000.

45

STEP 13
Peel ply is placed all over the lay out.

STEP 14
Perforated plastic is placed over peel ply.

STEP 15
Mosquito net is placed from R 2270 to R 11300.

STEP 16
Insulation Tape is placed centrally from the trailing edge at 735mm
from R 2270 to R 11000.

STEP 17
Spiral Tube is placed over the insulation Tape using T pipe at
R 2400.

VACUUM APPLICATION BEFORE INJECTION OF RESIN

46

STEP 18
Tacky Tape is placed outside the Vacuum point all along the
Flange to have a Vacuum plastic over the Mould. This is
referred as inside Vacuum. Outside with another Vacuum
Plastic is placed to protect the inner one.

STEP 19
Inner Vacuum is applied with the help of Vacuum pump to
maintain a pressure of 1 bar. Tolerance of drop in Vacuum of
30 Milibar is allowed for 10 Minutes.
STEP 20
After Resin infusion all along the layers heating at stage one
(400 C) Is continued till 30 minutes. After 30 minutes, stage two
heating is given (700 C) for a period of one hour. In stage three
heating is given then onwards for a period of one hour.

47

SPOILER WEB CAP MAKING

MATERIALS USED
a) Peel ply
b) CSM of width 50 mm
c) Double-sided Tape
d) Foam
e) G1+G1 fibre
f) Insulation paper
g) Spiral Tube
h) Tissue Paper
i) Tacky Tape
j) Epoxy Resin system

PROCESS
STEP 1
Cleaning of the Mould with NC-55 & Flange with Acmosion.

STEP 2
Placing of double sided tape for Adherence of the subsequent
Peelply.

STEP 3
Place Peel ply all over the Mould.

48

STEP 4
Place G1+G1 layer all over the Mould.
STEP 5
Put 10 mm Foam as per design. Gaps are filled with Cotton flock.

STEP 6
Again G1+G1 layer placed.
STEP 7
Insulation paper is placed centrally.
STEP 8
Spiral Tube is placed over insulation paper as per the design.
STEP 9
Place Injection T. The injection point is taken centrally.
STEP 10
Tacky Tape is placed outside Vacuum point all along the Flange
to have a Vacuum plastic over the Mould. This is referred as
inside Vacuum. Outside ,another Vacuum Plastic is placed to
protect the inner one.
STEP 11
Inner Vacuum is applied with the help of Vacuum pump to
maintain a pressure of 1 bar. Tolerance of drop in Vacuum of
30 Milibar is allowed for 10 Minutes.
STEP 12
Similarly tolerance of 30 Milibar is allowed for 3 Minutes in outer
Vacuum Plastic.

49

STEP 13
Once the Quality Dept. approves the Vacuum, then a drop
till 97 Milibar is done manually by regulation of valve.

STEP 14
Now apply Epoxy Resin system (Resin + Hardener) using 50%
each by proportion.

STEP 15
Once the infusion is completed Vacuum is dropped to 75 Milibar.
STEP 16
Once the exotherm is completed heating is provided for a period of
2 hour.

50

SPOILER GLUE CAP MAKING

MATERIALS USED
a) Peel ply
b) CSM of width 50 mm
c) Double sided tape
d) G1+G1 fabric
e) Tissue paper
f) Tacky Tape
g) Vacuum Plastic
h) Epoxy Resin System

PROCESS
STEP 1
Cleaning of the Mould with NC-55 & Flange with Acmosion.
STEP 2
Placing of double sided tape for Adherence of the subsequent Peelply.
STEP 3
Three layers of G1+G1 Error! Not a valid link.is placed from R 2254
to R 8000.
STEP 4
Re-enforcement layer for crane transport. Three G1+G1 layer
(Length400mm, and width 100mm) are placed starting from R 4950
to R 5000 and R 5050 respectively.
51

STEP 5
Put CSM layer over the one side of layers laid leaving a gap of 200
mm on either side of the Mould.
STEP 6
Place Vacuum flash absorbent all along the Vacuum point.
STEP 7
Inside & outside Vacuum Plastic is placed .
STEP 8
Tissue Paper is placed between two successive Vacuum points.
STEP 9
Tacky Tape is placed outside the Vacuum point all along the
Flange to have a Vacuum plastic over the Mould. This is
referred as inside Vacuum. Outside with another Vacuum Plastic
is placed to protect the inner one.
STEP 10
Inner Vacuum is applied with the help of Vacuum pump to
maintain a pressure of 1 bar. Tolerance of drop in Vacuum of
30 Milibar is allowed for 10 Minutes.
STEP 11
Similarly tolerance of 30 Milibar is allowed for 3 Minutes in outer
Vacuum Plastic.
STEP 12
Once the Quality Dept. approves the Vacuum, then a drop
till 97 Milibar is done manually by regulation of valve.

STEP 13
Now apply Epoxy Resin system (Resin + Hardener) using 50%
each by proportion.
52

STEP 14
Once the infusion is completed Vacuum is dropped to 75 Milibar.
STEP 15
Once the exotherm is completed heating is provided for a period of
2 hour.

HEATING OF SPOILER GLUE CAP

53

SHELL MAKING
MATERIALS USED1. The Glass Fiber used are R-1/0-1188-M70 , G-1/1/0/1-114
M100 , G2-/1/0/1-1169 ,G1 + G 1, G2-/1/0/1-1169 powder
coated.
2. Peel ply
3. CSM of different width
4. Double-sided Tape
5. Masking tape
6. Balsa and Foam
7. Perforated Sieve
8. Spiral Tube and injection T
9. Vacuum plastic
10.Tissue Paper
11.Tacky Tape
12. Epoxy Resin System.

E_48/1 Blade Manufactured in two parts.

A. Suction Shell and
B. Pressure Shell.

54

A. SUCTION SHELL MAKING

STEP 1
Cleaning of Suction Mould by using Acmosion at Flange area and
NC-55 on Shell surface.
STEP 2
To adhere Peel ply on Mould, Double-sided Tape is used.
STEP 3
Peel ply is placed over the Mould at
L / E and T/ E 200 mm width from R1100 to R 5800
Peel ply over Spoiler area 100mm width.
Peel ply 25 mm width for bonding of V profile R11500 to R
24000.
Peel ply on outer surface from R 1100 to R 2200.
STEP 4
Shell Lamination
a. Two layer of CSM apply over FRP strip from R 1100 to R1900
(Which is used for Resin transfer) at middle of the Mould having the
width of 100 mm and 200 mm width up to R 3000.
b. One surface layer apply width of 500 mm
(Apply leading side to trilling side at 100 mm step).
c. Outer G2 sub pocket apply.

Layer 1 width 420 mm

Layer 2 width 450 mm

Layer 3 width 480 mm
d. Apply Special G1 layer (G-1/1/0/1-114 M100) throughout
the Mould.

55

e. Outer G2 pocket apply (G2-/1/0/1-1169)

Layer 1 R 1100 to R 8800 (T/E side)
R 1100 to R 7600 (L/E side)

Layer 2 R 11oo to R 7600 (T/E side)
R 1100 to R 6400 (L/E side)

Layer 3 R 1100 to R 6400 (T/E side)
R 1100 to R 5200 (L/E side)
f. Three layer of R1 apply. (R-1/0-1188-m70, 100mm width)

Layer 1 R 6700 to R 21200

Layer 2 R 7000 to R 20100

Layer 3 R 7600 to R19000
g. Preform apply from R 1100 to R 3900.
h. One layer of CSM width 700 mm from R 1100 to R 22500.
i. Sparboom apply from R 1800 to R 22000.
j. CSM apply throughout the Sparboom.
STEP 5
Foam and Balsa Placing.
 L/E side
a. Balsa of 9.5mm from R 1800 to R15000.
(Chamfering 150mm at R 1800, Chamfering 30 0 at R
15000)
b. Foam 5mm from R 15000 to R 23900.
(Chamfering 130mm at R 23900)
 T/E side
a. Balsa of 15.9mm from R 1800 to R 6000 (Chamfer 300 at
R 6000)
b. 14 mm Foam from R 6000 to R15000 (Chamfering both end
40mm)
c. Foam 8mm from 15000 to R 17500. (Chamfering both end
300)
d. Foam 5 mm from 17500 to 22000.

56

STEP 6
Apply R1 layer at T/E side.

Layer 1 R 7900 to R 21900

Layer 2 R 8200 to R 21350

Layer 3 R 8500 to R 20800

Layer 4 R 8800 to R 20250.
STEP 7
Inside G2 pocket apply (G2-/1/0/1-1169)

Layer 1 R 1100 to R 8200(L/E)side

Layer 1 R 1100 to R 8200(T/E) side

Layer 2 R 11oo to R 7000(L/E) side

Layer 2 R 1100 to R 7000(T/E) side

Layer 3 R 1100 to R 5800 (L/E) side

Layer 3 R 1100 to R 5800 (T/E) side

Layer 4 R 1100 to R 4600 (L/E) side

Layer 4 R 1100 to R 4600 (L/E) side.
STEP 8
Last (G2-/1/0/1-1169 layer )
1) R 1100 to R 10200 (throughout the Mould) G2
apply (G2-/1/0/1-1169)
2) R 10200 to R 24000 (throughout the Mould) G1+ G1
layer.
STEP 9
Five layer of G1+ G1 (at tip side)

Layer 1 180.x 340

Layer 2 160x 320

Layer 3 140x300

Layer 4 120x280

Layer 5 100x260.
STEP 10
Inside G2 (G2-/1/0/1-1169) sub pocket

Layer 1 Width 420 mm

Layer 2 Width 450 mm

Layer 3 Width 480 mm
57

STEP 11
Apply peel ply through out the mould.

SUCTION SHELL MAKING

STEP 12
Infusion plan & Vacuum application.
Resin infusion T is placed at R1400, R2700& R 15500.
CSM is place according to design for Resin infusion.
Peel ply is applied all over the Mould surface.
Tissue Paper is placed every half-meter at Mould edge
before inside Vacuum.
Place Vacuum flash absorbent all along the Mould.
Inside & outside Vacuum Plastic is placed.

58

 Tacky Tape is placed all along the Flange area. Than

Vacuum is applied this is referred as inside Vacuum.
Outside another Vacuum Plastic is placed to protect the
inner one.
Inner Vacuum is applied with the help of Vacuum pump to
maintain pressure of 1 bar. Tolerance of drop in Vacuum of
30 Milibar is allowed for 10 Minutes.
Similarly tolerance of 30 Milibar is allowed for 3 Minutes in
outer Vacuum Plastic.
Once the Quality Dept. approves the Vacuum, then a drop
till 97 Milibar is done manually by regulation of valve.
Once the infusion is completed Vacuum is dropped to 75
Milibar.
Once the exotherm is completed heating is provided for a
period of 4 Hour at 600 C.

59

B. PRESSURE SHELL MAKING

STEP 1
Cleaning of the suction mould by using Acmosion at flange area and
and applying NC-55 on Shell surface.
STEP 2
To adhere Peel ply on Mould, Double-sided Tape is used.
STEP 3 Peel ply is placed over the Mould at
L / E and T/ E 200 mm width from R1100 to R 5800.
Peel ply over Spoiler area 100mm width.
Peel ply 25 mm width for bonding of V profile R11500 to R
24000.
Peel ply on outer surface from R 1100 to R 2200.
STEP 4 Shell Lamination
a. Two layer of CSM apply over FRP strip from R 1100 to R1900
(which is used for Resin transfer) at middle of the Mould having the
width of 100 mm and 200 mm width up to R 3000.
b. One surface layer apply width of 500 mm.
c. Outer G2 sub pocket apply.

Layer 1 width 420 mm

Layer 2 width 450 mm

Layer 3 width 480 mm
d. Special G1 layer apply (G-1/1/0/1-114 M100) throughout
the Mould.
e. Outer G2 pocket apply (G2-/1/0/1-1169)
Layer 1 R 1100 to R 8800 (T/E side)
R 1100 to R 7600 (L/E side)

60

Layer 2 R 11oo to R 7600 (T/E side)

R 1100 to R 6400 (L/E side)
Layer 3 R 1100 to R 6400 (T/E side)
R 1100 to R 5200 (L/E side)
f. 5 layer of R1 apply. (R-1/0-1188-m70, 100mm width).

Layer 1 R 6400 to R 22300

Layer 2 R 6700 to R 21200

Layer 3 R 7000 to R 20100

Layer 4 R 7300 to R 19000

Layer 5 R 7600 to R 17900
g. Preform apply from R 1100 to R 3900.
h. One layer of CSM width 700 mm from R 1100 to R 22500
i. Sparboom apply from R 1800 to R 22000.
j. CSM apply throughout the Sparboom.
k. Balancing Chamber layer

Start from R15950

End at R 18050.
STEP 5
Foam and Balsa Placing
 L/E side
a. Balsa of 9.5mm from R 1800 to R15000.
(Chamfering 150mm at R 1800, Chamfering 30 0 at R
15000)
b. Foam 5mm from R 15000 to R 23900.
(Chamfering 130mm at R 23900)


T/E side
a. Balsa of 15.9mm from R 1800 to R 6000 (Chamfer 300 at
R 6000)
b. Foam 14 mm from R 6000 to R15000 (Chamfering both end
40mm)

61

c. Foam 8mm from 15000 to R 17500. (Chamfering both end

300)
d. Foam 5 mm from 17500 to 22000.
STEP 6
Apply R1 layer at T/E side. (Trailing edge side)

Layer 1 R 7900 to R 21900

Layer 2 R 8200 to R 21350

Layer 3 R 8500 to R 20800

Layer 4 R 8800 to R 20250.
STEP 7
Balancing Chamber layer

Start from R16000

End at R 18000.
STEP 8
Inside G2 pocket apply (G2-/1/0/1-1169)

Layer 1 R 1100 to R 8200(L/E) side

Layer 1 R 1100 to R 8200(T/E) side

Layer 2 R 11oo to R 7000(L/E )side

Layer 2 R 1100 to R 7000(T/E) side

Layer 3 R 1100 to R 5800 (L/E) side

Layer 3 R 1100 to R 5800 (T/E) side

Layer 4 R 1100 to R 4600 (L/E) side

Layer 4 R 1100 to R 4600 (T/E) side.
STEP 9
Last (G2-/1/0/1-1169) layer
1)
R 1100 to R 10200 (throughout the Mould) G2
apply
(G2-/1/0/1-1169)
2) R 10200 to R 24000 (throughout the Mould) G1+ G1
layer.

62

STEP 10
Five layer of G1+ G1 (at tip side)

Layer 1 180.x 340

Layer 2 160x 320

Layer 3 140x300

Layer 4 120x280

Layer 5 100x260.
STEP 11
Inside G2 (G2-/1/0/1-1169) sub pocket

Layer 1 Width 420 mm

Layer 2 Width 450 mm

Layer 3 Width 480 mm.
STEP 12
Infusion plan & Vacuum application.

Resin infusion T is placed at R1400, R2700& R 15500.

CSM is place according to design for Resin infusion.

Peel ply is applied all over the Mould surface.

Tissue Paper is placed every half-meter at Mould edge before

Inside Vacuum.

Place Vacuum flash absorbent all along the Mould.

Inside & outside Vacuum Plastic is placed.
Tacky Tape is placed all along the Flange area. Then Vacuum is
applied this is referred as inside Vacuum. Outside another
Vacuum Plastic is placed to protect the inner one.
Inner Vacuum is applied with the help of Vacuum pump to
maintain a pressure of 1 bar. Tolerance of drop in Vacuum of
30 Milibar is allowed for 10 Minutes.

63

 Similarly tolerance of 30 Milibar is allowed for 3 Minutes in

outer Vacuum Plastic.
Once the Quality Dept. approves the Vacuum, then a drop till
97 Milibar is done manually by regulation of valve.
Once the infusion is completed Vacuum is dropped to 75
Milibar.
Once the Exotherm is completed heating is provided for a
period of 4 Hour at 600 C.

PRESSURE SHELL MAKING

64

WEB JOINING
MATERIALS USED
a) Epoxy paste
b) Paste applicator
c) G1+ G1 layer
d) Hot Blower
e) Epoxy Resin system

After the curing of Shell following prior activities are to be carried out for
Web joining process.

PROCESS
STEP 1
The Vacuum Plastic, which contain Different items Vacuum film, PVC
Angle, Tacky Tape, Perforated PE, Non-wowing cloth are taken out
from the Mould surface.
STEP 2
Injection pipe remove from the Mould surface.
STEP 3
Injection point sanding & lamination.
STEP 4
Peel ply fabric is taken out from the surface of Mould & paste
coating of gluing area.
STEP 5
Epoxy paste place at required glue area with the help of glue applicator.
65

APPLICATION OF EPOXY PASTE

STEP 6
Web put at R 2700 & fix with the help of fixture and End at R 21800
distance between two Webs is 260 mm at R 2700 and at R 21800
is 200 mm.
STEP 7
Flash out paste is removing with the help of glue applicator and brush.
STEP 8
Two G1+ G1 layer of 100 mm width, laminate with Shell.
1). 60 mm with Web & 40 mm with Shell
2). 40 mm with Web & 60 mm with Shell
STEP 9
Remove air with the help of hard roller.
STEP 10
Heating is given for a period of 2 hour at the temperature 700 800 C
by using hot water circulation.
66

STEP 11
Fixture is applied for heating.
STEP 12
Hot Blower applies at Root side for further heating.

A JOINED WEB KEPT OPEN TO HOT AIR

67

SHELL JOINING
MATERIALS USED
a) Glue Caps
b) Tip
c) Epoxy paste
d) S.S. 180 mm spokes
e) Paste applicator

PROCESS
After the curing of Shell following prior activities are to be carried out for
Shell joining process.
STEP 1
The Vacuum Plastic, which contain Different items Vacuum film,
PVC angle, Tacky Tape, Perforated PE, Non wowing cloth are then
taken out from the Mould surface.
STEP 2
Remove injection pipe from the Mould surface.
STEP 3
Injection point lamination.
STEP 4
Balance Chamber made ready & joining on pressure Shell at
R 16250 mm.

68

STEP 5
Glue Caps (Leading & Trailing edge) are make ready for joining
(Peel ply fabric is taken out from the surface of Glue Caps) & placed
on Edges of Mould with the help of S.S. spokes of 180 mm & fiber
Washer is used.
STEP 6
L/E & T/E Glue Caps make ready for joining (Peel ply fabric is taken
out from the surface of Glue Caps).
STEP 7
Tip connecting with Glue Caps.
STEP 8
Glue gap checking of Mould.
STEP 9
Peel ply fabric of various widths is taken out from the surface of
Mould.
STEP 10
Epoxy paste is used for entire joining process, which contains
Epoxy Resin G-3, Hardeners for H-137 at Ratio of 100: 45
respectively.
STEP 11
Epoxy paste is applied on Web surface with the help of glue
applicator.
STEP 12
Glue Caps leading & trailing edge are placed on edges of Mould &
glue with Epoxy paste.

69

STEP 13
The Mould is closed and S.S. spokes pulled with the help of spokes
puller by using Air gun than inside flash out paste is remove &
heating is given for a period of 6 hour at the temperature 700 - 800 C
by using hot water circulation.
STEP 14
Hot Blower applies at Root side for further heating.

JOINING OF THE PRESSURE AND SUCTION SHELLS

70

SHELL RELEASING
PROCESS
STEP 1
After getting desired TG (600 C) value stop the heating and open
the spoke puller.
STEP 2
Release Suction Shell with the help of Crain and turning device.
STEP 3
Cool the Mould up to 500 - 550 C in pressure Shell.
STEP 4
Release the Blade with the help of fixture ( cut the flesh out
paste at required radial position for fixture ).
STEP 5
Release the Blade from pressure shell.

RELEASING OF BLADE BY CRANE

71

DEBURRING PROCESS
MATERIALS USED
a) G1+G1 layer & (G2-/1/0/1-1169)
b) Paste 20
c) V shape and D shape.

PROCESS
STEP 1
Flash Cutting.
The paste i.e. flashed out during the joining of two Shells is streamed
according to the profile of the Blade.
STEP 2
QA Inspection.
STEP 3
V shape and D shape.
V shape is fixed over blade according to design side with the help of
Paste 20 glue & D shape is laminated with 100 mm G1+G1 layer
and given a heating of 4 hour respectively with the help of special
heating systems.
STEP 4
Leading & Trailing.
From .R 2000 to R 5000, three layer of G1+ G1 having width of 200
mm each are placed by hand lay-up technique on L/E and T/E side
and given a heating of 4 hour with the help of hot blower.

72

STEP 5
Inner and outer.
To maintain a thickness of 57 mm of the Root section inner and outer
Lamination is done using G2 (G2-/1/0/1-1169) layer by hand lay up
technique.

V AND D PROFILE FIXING

73

SAWING AND DRILLING

P R O C ES S
MATERIALS & MACHINES USED
a) Sawing and Drilling machine
b) Flange
c) Stud bolt
d) Paste 20
After completion of the Debarring process the Blade is placed for the sawing
& drilling machine.

PROCESS
STEP 1
Place Blade on fixture.
STEP 2
Sawing is done by Sawing and Drilling machine (100mm from the
Root).
STEP 3
Marking for sawing of the Root fixed at R 2100.
STEP 4
Marking is fixed for the drilling as per the design.

74

STEP 5
QA Department checks the marking.
STEP 6
Then drilling is done by machine. The drilling machine drills two
kindsof holes.
a. Cross holes (O .450 )
b. Longitudinal holes (O .230)
STEP 7
Place Flange on the Root side with the help of Paste 20 glue &
heating is applied for 4 hours.
STEP 8
The stud bolt is placed on Root side with the help of Paste 20 glue
and heating is applied for 4 hours.

SAWING AND DRILLING MACHINE

75

SPOILER FIXING
MATERIALS USED
a) Gel coat
b) Resin hardener paste
c) Screw of 2.5 mm
d) Layer of G1+G1

PROCESS
STEP 1
The Spoiler is affixed to the Blade after stud bolt joining.
STEP 2
Fixture for fixing of Spoiler is fixed to the stud bolt so that the
Spoiler is fixed at R 2254 location of the Blade.
STEP 3
The Blade is made ready for Spoiler fixing by removing the peelply
over the bonding area.
STEP 4
Gel coat is then applied over the D shape.
STEP 5
The Spoiler is trimmed and made ready for fixing on the Blade.

76

STEP 6
Resin hardener paste is applied on the bonding area between the
Blade and Spoiler.
STEP 7
Screw of 2.5mm is used to adhere the Blade with the Spoiler.
STEP 8
Layer of G1+G1 of width 200x200mm to the inner edge of Spoiler,
so that better adherence of the Blade with the Spoiler takes place.
STEP 9
Heating is provided to the Spoiler Glue for attaining required TG
( 600 C ) value.

BLADE AFTER SPOILER FIXING

77

FINISHING PROCESS
MATERIALS USED
a) M5 screw
b) 60 Grid paper, 120 Grid paper
c) Bergolin Paste
d) Kantensutz Paint
e) Aluminum primer
f) Topcoat

PROCESS
After checking TG values of the Blade Viz. Stud Bolt, V profile Spoiler
Glue is checked by quality people, and then Blade is allowed to load on
finishing stand.
STEP 1
The V profile and the Tip are connected to each other by M5 screw.
The joint of the FRP and the Tip is strengthen by using counter
shock M6 screw (14 Nos) according to the design.
STEP 2
The flesh of L/E is trimmed carefully to match with the profile of
Leading Edge.
STEP 3
Using 60 Grid paper full sanding of the surface of the Blade is done.
STEP 4
PU paste called as bergolin is used to level the profile Viz. L/E, V
profile, and Root surface. This is allowed to 2 hour.
78

STEP 5
Complete sanding of the bergolin is done and the surface is leveled to
the Profile of the Blade.

SANDING MACHINE

SAND PAPER

SANDING OPERATION

79

STEP 6
Kantensutz is applied from R 14000 to R 24000. It is allowed to cure
for four hour.
STEP 7
Aluminum primer is applied from R 11000 to R 24000 and allowed to
Cure for 2 hour.
STEP 8
Three coat of primer is then applied to the entire surface of the Blade.
Between every coat of primer gap of 45 Minutes is taken for drying
the Primer.

APPLICATION OF ALUMINIUM PRIMER

80

STEP 9
Three topcoats are applied to the Blade giving a gap of 45 minutes.
STEP 10
The Blade is then checked by the Quality Dept. for any touch up
required.
STEP 11
The Blade is then unloaded and given to Dispatch Dept. for further
work.

TOPCOAT BEING APPLIED

81

DISPATCH
MATERIALS USED
a) Discharge ring
b) G1+G1 layer
c) Discharge box
d) Stud Paste
e) Polyester Resin Hardener System
f) Brush

PROCESS
STEP 1
Discharge ring is located on the Root section according to design.
STEP 2
Connection of lightening protection is ensured.
STEP 3
Inside cleaning for dust is done.
STEP 4
Lamination at the start of Web is done using G1+G1 layer of
600x150 mm.
STEP 5
Discharge box is connected to the leading edge flat aluminum Plate.

82

STEP 6
Ceiling of the stud paste over the locus of the drilling is
done for stud Bolt.
STEP 7
Brush at the edge of the Spoiler is placed to avoid dust from entering
the Blade.
STEP 8
Pair of Drainage holes are put at the end of blade on T / E side.
STEP 9
The Blades are now ready for balancing. Momentum of the three
Blades is done by pouring lead and Resin hardener system, keeping
one of the Blades as reference.

BLADE BALANCING ( TIP SIDE )

83

BLADE BALANCING ( ROOT SIDE )

STEP 10
The QA Department ensures Quality of the Blade.
STEP 11
The 0 Deeg. Marking is done on the reference bolt.
STEP 12
The three Blades are covered & loaded on the trailer to be dispatch
as finished product.

BLADES READY FOR DISPATCH

84

LINE DIAGRAM OF BLADE MAKING

PREFORM MAKING

MOLD CLEANING & REALEASE AGENT

APLY ON MOLD SURFACE

SPARBOOM MAKING

DRY GLASS FIBRE LAYERS LAY

UP ON
MOULD SURFACE

1) L/E GLUECAP
2) T/E GLUECAP
3) SET OF WEB

ONLINE Q.A CHECK

VACUUM &
HEATING
RESIN INJECTION

4) BALANCING CHAMBER
5) TIP

ONLINE Q.A. CHECK

VACUUM &
HEATING

curing

SUCTION SHELL
HEATING
PRESSURE & SUCTION SHELL
JOINING

ONLINE Q.A CHECK

85

BLADE RELEASING

FLASH CUTTING AND

SLOTING

V & D PROFILE
T/E & L/E LAMINATION

WELDING

SAND
BLASTING

V & D PROFILE FIXING

& DISCHARGE RING FIXING

Q.A. CHECKING
1.BLADE ANGLE
2. PCD CHECK
3. THICKNESS

SAWING AND DRILLING

FLANGE
LAMINATION

GRP COVERING ON
TBOLT

STUD & BOLT FIXING

SPOILER
MANUFACTURING

SPOILER FIXING TO
BLADE

86

Q.A CHECK

FINISHING

DISHARGE BOX &

ADAPTER COVER FIXING

BLADE BALANCING

FINAL Q.A CHECK

BLADE DISPATCH

87

TEC H N I C A L D ETA I LS
Rated capacity
Rotor diameter
Cut in wind speed
Rated wind speed

800kw
48 m
2 m/sec
14 m/sec

Rotor with Pitch control :

Type
Direction of rotation
No of blades
Swept area
Blade material
Rotor speed
Pitch control

Up wind rotor with active pitch control

Clockwise
3
1810 m sq.
Fibre glass (reinforced epoxy) with integral
Lightning protection
variable, 16-31.5 rpm
three synchronized blade pitch system with battery
back up

Generator :
Hub
Bearings

Grid feeding :
Braking system :
Yaw control

rigid
tapered roller bearings
AC-DC-AC through converter inverter
3 independent aero brakes with emergency power
back up
active through adjustment gears, friction damping

Tower:
Steel tubular
Concrete

56 m
74 m

88

CRITICAL PARAMETERS
MOULD TEMPERATURE DURING LAY-UP
LAY-UP PROCEDURE
EFFECTIVENESS OF VACUUM
RESIN:HARDENER RATIO
RESIN HARDENER TEMPERATURE DURING
INFUSION
MOULD TEMPERATURE DURING INFUSION
FLOW OF RESIN DURING THE PROCESS
TEMPERATURE DURING EXOTHERM AND
CURING
PAINTING AND FINISHING OF THE SURFACE

89

MOLD TEMPERATURE DURING

LAY-UP
Before starting the lay up procedure of the fibres the primary step is to set
the temperature of the mold to the desired value. The temperature of the
mold can be controlled by the heating system attached to the mould. The
heating system is provided with a small indicator screen that indicates the
temperature of the mold. The operator sets the temperature that is to be
maintained throughout the lay-up process, and the heating system
automatically maintains that temperature during the operation until and
unless someone changes it.

The standard temperature for the lay-up process of the E-48 blade
parts is 40-450 C.
If the temperature, which is mentioned above, is not kept constant and
increased to a higher value then the layers of the glass fibres will get heated.
These layers will not be cooled on the application of the vacuum and when
we infuse the resin and hardener mixture in between these layers, there
would be an early curing of the resin, before the desired time period. Due to
this pre-mature curing, the resin will not cover the whole of the glass fibres
and there would be some dry portions or patches where the resin would not
have reached.
On the other hand, if the temperature is reduced to a little extent,
then the layers will be cooled. These cooled layers will not be affected by
the vacuum application and during the infusion process, when the resin will
pass through these layers, the crystallization of the resin will take place. Due
90

to this crystallization phenomenon coming in to picture, the crystallized

resin would acquire certain portions in the product and would hinder the
distribution of resin to other portions connected to that particular area. As a
result there would be the presence of dry patches or resin free voids in the
final molded product.
So it is clear from the above two factors that the controlling of temperature
during lay up is a very important factor in order to prevent any defect in the
molded product. Therefore any deviation, whether increment or decrement
from the standard temperature would be responsible for the appearance of
dry patches.In order to prevent these dry patches we have to maintain the
recommended temperature constant through out the whole lay up process.

SCREEN SHOWING THE TEMPERATURE OF THE MOULD

91

LAY-UP PROCEDURE
The procedure given previously for each part has to be strictly followed in
order to prevent any disconfirmation from the standard design. Any kind of
deviation, whether in terms of order of lay-up of glass fibres, peel ply,
perforated plastic, distribution net; their dimensions; shape; chamfering of
balsa and foam, would be responsible for the presence of defect in the final
product. So in order to avoid this problem, the workers have to be very
attentive and careful during the lay up process.
Some important factors to be considered during the process of lay up are
given below : The workers while laying should wear hand gloves in order to avoid
any dust or foreign particle entering in between the layers to cause the
dry patches.
 Moreover there is moisture present in the hands, which gets absorbed
to the glass fabric and is entrapped in between the layers. Since
vacuum is applied in the process, so these do not evaporate out to
atmosphere on heating and remain there collected in certain areas.
During the infusion process, these areas do not allow the resin to soak
the glass fabric as a result of which there is absence of resin in these
portions causing the dry patches or white patches to appear on the
surface after the process is complete.

92

 The glass fibres should not be kept open to atmosphere as they can
easily acquire moisture and dust particles suspending in the
environment. They should be well covered with a suitable plastic
cover in recommended conditions.
 The lay up should not be done if the humidity is more than 97%.
 The fibres should not be folded too much during the lay-up as some of
the individual fibre may break.
 The laying process of the fibres should be done in a separate area free
from any dust producing environment, such as an area where the
operations like sanding is being done.

93

EFFECTIVENESS OF VACUUM
 Inner Vacuum is applied with the help of Vacuum pump to maintain a
pressure of 1000 mbar. Tolerance of drop in Vacuum of 20 mbar is
allowed for 10 minutes.
 Then the outer vacuum is applied. A tolerance of 30 mbar is allowed
for 3 minutes in outer vacuum plastic.
 Once the vacuum is found to be perfect i.e. there are no leakages
detected, and then a drop of 50 mbar is allowed for the infusion
process to occur.
 Once the resin has fully wetted the glass fabric, then the vacuum is
dropped to 500 mbar.

VACUUM PUMP

94

The proper application of vacuum is a very important, in order to avoid any

kind of defect in the blade parts. Usually there are some leakages during the
application of vacuum. These leakages if not detected properly and sealed,
can cause air entrapment in the glass fabric layers. When we infuse the resin
in between the layers, the resins do not cover the air-entrapped area. So these
portions in which the resin is not there, naturally contains some dry patches
or resin free voids.
Another cause for the voids is that the vacuum applied is
not sufficient for the resin to flow properly i.e. there is not enough pressure
difference for the resin to fill in the glass fabric layers. Thus there is
inadequate amount of resin to cover the whole of the glass fabric, leaving
some dry patches.

95

RESIN-HARDENER
TEMPERATURE
DURING INFUSION
The temperature of resin and hardener during the infusion time period is also
an important factor for the occurrence of defects. Normally the temperature
is kept in the desired range, but sometimes it shoots up more than the
allowable range due to the ignorance of the workers.
If we infuse the resin and hardener at temperature more than the
recommended, then the resin and hardener will cure at a much early time
period, without covering the whole of the fabric. Thus we see that there are
some dry patches or areas where the resin has not reached, occurring in the
blade parts.

The standard temperature of resin and hardener during infusion is

30 400 C.
The epoxy resin and hardener temperatures have the following positive and
negative effects on usability and the quality of the finished product:
 The mixture loses viscosity as the temperature rises; the mixture
becomes more fluid, which improves the flowing quality of the
components in the pipeline systems.

96

 Warm resin mixtures allow for improved wetting of the fibres during
processing. However, the pot life of the resin/hardener mixture
decreases as its temperature rises.
 At low temperatures ( 10-150 C ) some parts of the resin component
can crystallize and sink to the bottom of the container. Removing the
mixture in this state and mixing it with the hardening component
would create an unserviceable epoxy resin mixture.

 The working time ( pot life ) of the mixture increases at low

temperatures, however, when the temperature drops below 150 C the
curing process more or less stops.

HIGH TEMPERATURE ( INCORRECT )

97

TEMPERATURE IN THE DESIRED RANGE ( CORRECT )

98

TEMPERATURE DURING
INFUSION
The temperature during the infusion time period is also an important factor
for the occurrence of some deviations or defects. Normally the temperature
is kept in the desired range, but sometimes it shoots up more than the
allowable range due to the carelessness of the heating system operator or
some fault in the machine.

The standard temperature of the mold during the infusion time

period is kept at 420 C.
The defects in the parts occur if the mould temperature is increased, say to
600 C, then the glass fabric and other supporting materials like distribution net,
CSM etc, will be heated. When the resin will pass through these materials, and
the upper layers of the glass fabric, it will start to get cured. In this way these
upper layers would unnecessarily create a blockage of resin to the lower
layers. So the lower layers would not be fully wetted by the resin in the normal
time period creating some dry patches or white patches on the surface of the
molded product.
Another possible reason for the occurrence of the defects could be the nonuniform heating of the mould. The temperature during the infusion process is
controlled by the heating system. Temperature controlled molds usually
employ internal tubing to circulate a temperature-adjusted fluid through the
mold heat sink. The fluid (usually water) maintains the temperature,
sometimes heating and sometimes cooling the mold, while the heat sink acts

99

to moderate the temperature and provide a consistent baseline. Temperature

controlled molds provides a molding consistency that promotes quality along
with fast cycle times. The process can be optimized when mold temperature
is properly managed.
But sometimes the mould is not heated uniformly
throughout its entire length. Thus while the infusion process is going on, the
resin is more heated at some places than the other. Thus the place where the
resin is over heated, starts to gets cured before the desired time period and
other places are deprived of the resin showing some resin free voids on the
surface of the molded blade part.

INFUSION PROCESS GOING ON

100

FLOW OF RESIN
The proper flow of the resin is another factor for the non-occurrence of the
dry patches or white patches. In the resin flow channel there should not be
any hindrance to cause the accumulation of resin at certain areas. In this case
the importance of supporting materials is realized for helping in the proper
flow of resin to all the glass fabric layers. The spiral tube is the only medium
through which the resin first enters. So the spiral tube has to be given great
importance, besides the other supporting materials.

The standard diameter of spiral tube is 11.50 mm.

This diameter has to be maintained throughout the entire length of the spiral
tube i.e. it should have a uniform cross section. Any deviation from this
standard value would have a direct impact on the resin flow. If at some
places the diameter is reduced, then naturally, less resin would flow from
that area as compared to areas where the diameter is normal.

SPIRAL TUBE

101

Some important points, which should be taken into consideration are : The spiral tube should not loose its uniform diameter during the
application of vacuum. It should be hard enough to resist the force
applied by the vacuum pump.

The spiral tube should be made of the material, which would not deform
and loose its shape at the cross section under the heating conditions,
during the infusion time period. This would create some portions of the
tube thinner than the other causing insufficient flow of resin.

Likewise all the supporting materials such as distribution net, perforated

film etc, should not loose their properties during the application of heat
and vacuum.

102

TEMPERATURE DURING
EXOTHERM AND CURING
Temperature rise during the exotherm is a very important consideration for
the occurrence of dry patches. During this time period because of the
exotherm nature of the interaction between the resin/hardener and the glass
fibre, temperature of the system automatically increases. It increases from
400 C at the infusion time to 650 C. it is at this time period that no external
heat is supplied to the mould. If we apply any kind of heat then the resin will
not cure properly and some dry patches would be there.

HEATING SYSTEM

103

After the exothermic rise of the temperature, the system is again cooled to
420 C. then after it is heated upto 850 C in about two and half hours. Then
again it is cooled by the heating system. In the heating system the heating
medium is circulated throughout the mould to provide uniform heating. In
case of cooling the mould the heating medium is cooled by slow addition of
small amount of the same cooling medium but at a temperature much lower.
So this process takes a little bit of time as the mould cools slowly and
slowly.
If the heat supplied is very high right from the starting then the resin will
cure at much earlier time and it will not cover the whole of the fabric layers
leaving some dry or white patches in between the portions of the blade parts.
The important point to be taken care of is that the operation should be
carried out only on the specified temperature of each of the steps.

104

PAINTING AND FINISHING OF

THE BLADE SURFACE
VARIOUS STEPS OF PAINTING AND FINISHING
ARE:
1). SANDING :Sanding is the very first and important process in the finishing
of rotor blade. Sanding is used for creating roughness on the blade. The
roughness is required to the whole blade for creating the mechanical voids;
these mechanical voids increase the contact area of blade surface to the PU
paste. These are responsible for the bonding of PU paste to the blade surface.
Sanding is done with the help of sand paper. These sand papers are of the
different grits like 60, 80, 120, 240 etc. Sanding is done with the help of
different sand paper for different parts of the blade.
If the sanding operation is not done properly, then there would be inadequate
roughness and also the level will not be smooth, so the painting operation
will suffer. Moreover at some places, if there is too much sanding then the
sand paper would penetrate the surface and would reach the glass fibres,
causing it to break.

105

2). CLEANING :Cleaning is done for removing the dust from the blade
surface. Cleaning is done with the help of a cotton cloth or a tack cloth. Tack
cloth is actually a glue coated cloth, which helps in proper cleaning of blade
surface.
Improper or inadequate cleaning of the blade surface can cause entrapment
of foreign or dust particles. These particles results in defects like air bubbles,
pin holes, unlevelling, clogging etc.

3). APPLICATION OF PU PASTE :PU paste is used for leveling of the

Leading edge profile, V profile and Root surface. PU paste is used for
leveling of the different voids also. PU paste is used as the filler for different
voids appeared on the surface of blade after sanding is done. PU paste is also
used in repairing of different parts of blade.
After applying PU paste, the paste is allowed for curing. Curing
provide bonding of paste to the blade surface. The curing time for PU
paste is about two hours.
In the next step we check leading edge profile with the templates.
Templates are actually the apparatus used for checking the profile of
leading edge. The gap between blade surface and templates should be
<1mm. After this, sanding is done for best fit of the template with
abrasive paper grit 120 and eccentric grinder.

106

 First sanding is done only at radial position of template. If there is not

enough PU paste, then this position is marked and PU paste is applied
again. The same procedure is performed with the all other profile
checking template.
The spoiler area should be given the correct shape ( right angle ) at the
trailing edge.

Right

Wrong

There may be there may be some kind of flaws occurring like, air
bubble, holes, pinholes etc. These flaws are occur due to foreign
particles in the paint; improper cleaning (dust remaining on the
surface); improper mixing ratio of resin and hardener (100:175); use
of expired material etc. These flaws are removed with sanding at the
particular place and then applying paste again.

4). APPLICATION OF PRIMER :Primer used in the painting application is

a polyurethane based primer. It has excellent adhesion on blade surface. It
provides a bonding between topcoat and blade surface. Usually three coats
of primer are done for best results. The time gap between the coats is 40
minutes. Usually the primer is applied with the help of rollers.

107

 The mixing of components in the correct ratio is very important in

order to give the best bonding surface for the paint. The standard ratio
is
o PU based primer

100

o Hardener

66

o Accelerator

03

o Thinner

05

After the application of primer the wet film thickness of primer is

measured with thickness gauge. The standard thickness after three
coats of primer is 100 microns.

THICKNESS GAUGE IN MICRONS

Curing time for primer after three coats is at least five hours in
standard conditions. This may vary according to the environmental
conditions.
When the primer is becomes dry to touch, inspection is done by the
quality assurance department. There may be some flaws like air
bubble, dust, pinholes, and unleveled surface. These flaws occur due
to air entrapment, foreign particle (dust), improper mixing ratio, and

108

unskilled work. Flaws can be avoided by proper cleaning of blade

surface, using a proper workspace, proper mixing ratio and
recommended storage conditions. It should be stored between 5oC and
30oC in a dry, well ventilated place away from sources of heat and
direct sunlight, sources of ignition, oxidizing agents and strongly
alkaline and strongly acidic materials.
For repairing the flaws, first sanding of affected area is done with Grit
240 sanding paper and then paste is applied to the surface. After
applying the paste, primer is applied to that particular area.

5). APPLICATION OF TOP COAT :Top coat is the main paint system
applied to blade surface. Top coat has better weather resistance. Top coat is
applied for pore densing and providing smooth surface to the finished blade.
The mixing of components in the correct ratio is very important in
order to give the best finished surface . The standard ratio for different
components is
o PU based paint

100

o Hardener

100

o Thinner

65

The application of top coat can be performed by two ways:

By ROLLERS
By SPRAYING

109

The rollers are economical but the spraying painting gives a very
smooth surface finish. The time consumption is also very less in case
of spray painting.
After the application of top coat the wet film thickness of paint is
measured with thickness gauge. The standard thickness after three
coats of paint is 200 microns.
Curing time for paint after three coats is at least five hours in standard
conditions. This may vary according to the environmental conditions.
After curing the inspection of blade is done by the quality assurance
department. Defects that are occurring in painting are mainly
unleveled surface, air bubble, dust, roller marks and uncured paint.
These defects occur due to the air entrapment, foreign particle,
unskilled work, improper mixing and improper mixing ratio.
For repairing these defects, first sanding is done at the particular area
then PU paste is applied. After this primer and then top coat is
applied.
Taking few precautions like, proper cleaning at the place, proper
mixing and mixing ratio, skilled workers, can avoid defects. Also
paint should be stored between 5oC and 30oC in a dry, well ventilated
place away from sources of heat and direct sunlight, sources of
ignition, oxidizing agents and strongly alkaline and strongly acidic
materials.

110

 Finally the surface roughness measurement is done for checking the

smoothness of the finished surface. Surface roughness is measured
with Roughness tester. The Roughness tester used is known as
HOMMEL TESTER T500. The roughness for the finished blade
surface is about 5 microns.

111