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Day 35: Making Composite Materials

Day 35: Making Composite Materials. Some Matrix Materials Manufacturing Methods Structural Composites. Boeing 767. Airbus A380. http://www.airporttech.tc.faa.gov/safety/patterson2.asp. http://www.hsc.csu.edu.au/engineering_studies/aero_eng/2579/polymer_composites.html.

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Day 35: Making Composite Materials

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  1. Day 35: Making Composite Materials • Some Matrix Materials • Manufacturing Methods • Structural Composites

  2. Boeing 767

  3. Airbus A380 http://www.airporttech.tc.faa.gov/safety/patterson2.asp

  4. http://www.hsc.csu.edu.au/engineering_studies/aero_eng/2579/polymer_composites.htmlhttp://www.hsc.csu.edu.au/engineering_studies/aero_eng/2579/polymer_composites.html

  5. Composite Properties (Epoxy Matrix) Vf=0.6

  6. Boron Fibers are an uncommon addition –They are large and inflexible Epoxy Boron Graphite http://www.metallographic.com/Procedures/Applications.htm

  7. Boron Fiber - Chemical Vapor Deposition on a Tungsten Wire http://www.specmaterials.com/boronfiber.htm

  8. Carbon Fiber (Hexcel) http://www.hexcel.com/NR/rdonlyres/225E3CA5-965B-4B29-9A92-0CE184B1DDF3/0/CarbonFiber_SelectorGuide.pdf

  9. Carbon Fibers (Toray) http://www.toraycfa.com/pdfs/ToraycaSummaryDataSheet.pdf

  10. http://www.fibraplex.com/tow.asp

  11. Carbon Epoxy Composite Properties http://www.hexcel.com/NR/rdonlyres/225E3CA5-965B-4B29-9A92-0CE184B1DDF3/0/CarbonFiber_SelectorGuide.pdf

  12. Cost Comparison

  13. Matrix Materials for Composites • Function and Properties of the Matrix Material • Binding fibers together into a shape • Protect the fibers from damage • Serve as a barrier to failure. If an individual fiber fails, the failure will not spread. • Be very easy to bond to fiber • The matrix materials are usually polymers and are the”weak link” as far as operating temperatures are concerned.

  14. List of Matrix Materials, sometimes called “resins” • Polyester • Vinyl ester • Epoxy • Phenolic • PEEK

  15. Polyester • Very common polymer family. It can be thermoplastic and in this form is a common synthetic fiber. • Unsaturated polyesters are used in producing thermosets, (copoymerization with styrene) which are used as matrix materials. • Mostly in fiberglass. The bond is strong, and is particularly good at resisting water and chemical attack. • Cheap

  16. Vinyl Esters • Better than polyester, but a little more expensive. Gives upper end fiberglass. Glassair – first composite kit airplane.

  17. Epoxy • We have already discussed this one, a top of the line thermoset, very commonly used in aerospace composites.

  18. Others • Phenolics, high strength thermosets. Very good adhesives and high temperature uses. • PEEK. PEI (polyetherimide) PPS (polyphynolene sulfide) Very strong. Good at higher temperatures. This is a thermoplastic. In recent years, thermoplastic matrix materials have seen increased use. Tough, damage resistant, can be welded!

  19. Fabrication Processes • Pultrusion • Filament winding • Prepreg and Lay up

  20. Pultrusion • Quick, inexpensive way to make long fiber oriented composites. Fibers oriented. For the kind of stuff you make by extrusion. Hollow core is possible.

  21. Pultrusion Images http://www.henanpolymer.com/english/frp1.html http://www.aims-intl.com/images/grating___pultruded.gif

  22. Filament Winding • Filaments are carefully wound onto a mandrel after being wetted with resin. • When the desired number of windings is obtained, the object may be cured. • The manufactured object will often be cylindrical in shape.

  23. Filament Winding Images http://www.adoptech.com/pressure-vessels/main.htm http://imghost.indiamart.com/data/T/P/MY-718936/filament-wound-frp-pipes_10676686_250x250.jpg http://www.gilgwang.com/english/frp/img/grp03.gif

  24. Prepreg and Layup • You will see sheets of prepreg. They consist of the fiber and the uncured resin, with paper backing. • The sheets are applied, often by hand to a form, where they adhere. This is often done by hand, by expert workers. • Then cure.

  25. Images Prepreg must be stored at low temp. to avoid curing or drying out.

  26. Composite made by lay up

  27. Structural Composites • Sandwich Composites are an example of how different parts of a beam, plate or shell structure can be made in layers, in which each layer performs a function.

  28. Sandwich

  29. Types of Honeycomb • Aramid Fiber (Nomex®/Kevlar®) • Aluminum • Stainless Steel • Thermoplastic • Polycarbonate • Polypropylene • PVC • SAN • PE • ABS http://www.plascore.com/product-honeycomb-cores.htm?gclid=CJK_5_HP6p8CFQoNDQodExVGYg

  30. http://www.azom.com/details.asp?ArticleID=1092#_Honeycombs

  31. Application: Toyota Eagle 987 Fuselage is carbon fiber honeycomb composite

  32. GLARE • GLARE is used in aerospace structures. It is a composite in which layers of aluminum and fiberglass prepreg sheets are bonded together by epoxy. • Why not use carbon fiber? • The fibers are aligned in a way which is most favorable for load carrying. • Once fabricated, GLARE is then processed in much the same way that aerospace aluminum is.

  33. GLARE Images (Hybrid Composite) Outer layers of Aluminum act as protective barriers. Water absorption can be a problem. Here is reduced

  34. USE OF GLARE

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