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Composite Technology Laboratory

Composite Technology Laboratory. Rene Herrmann 2011. Composite material. Materials constist of at least 2 components, MATRIX and REINFORCEMENT. MATRIX is resin REINFORCEMENT is fiber Resin types are polyester, vinylester, epoxy

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Composite Technology Laboratory

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  1. Composite Technology Laboratory Rene Herrmann 2011

  2. Composite material • Materials constist of at least 2 components, MATRIX and REINFORCEMENT. • MATRIX is resin • REINFORCEMENT is fiber • Resin types are polyester, vinylester, epoxy • Fiber types are glas, carbon and aramid fibers (aramid is kevlar)

  3. Characteristics • Composites are unisotropic materials (theri characteristics depend on the direction (fibers) • Composites are chemically (rather) stable, strong and stiff as compared to their mass • Composites are more expensive than traditional materials (metal) and their strength collapses at around 200C.

  4. Composites challanges • Manufacturing of composite products is complex and often slow. • Interconnections between composites are difficult, optioins are seconary bonding and clueing • Composites degrade in UV light and need surface coatings that protect the resin MATRIX • Composite manufacturing requires a mould, form or plug to laminate on

  5. Composite moulds • The product must be laminated, a mould is needed • Moulds must release the laminate after it has been made (release agent on many such are needed) • Moulds must have a better surface finish than the product you are making. • Moulds are often milled and then polished. • Hand polishing is done until until 400 sandpapper and 800 to 1200 (2000) with water sandpapper and after that with polishing machine to ’optical’ surface finishes • Hand polishing takes 20 to 30 hours/m^2, this is what makes mould costs high.

  6. Composite manufacturing • Composites are LAMINATES, sometimes with a surface finish or without, in later case they are often painted later. • Composites are made because of the strength to mass ratio or because they are chemically corrosion resistant • Strength is defined by where is the young modulus and is the strain in the composite.

  7. Basic composite strength • Strength is . Force is and is cross section to force. • The composite breaks if the strain of EITHER RESIN or FIBER is reached. • The youngs modulus resisting the strain in the material is actucally a function of youngs modulus of both resin and fiber and their VOLUME FRACTION • Composite youngs modulus is . The volume fraction is . • The above equation is approcximative because it does not contain the volume fraction of VOIDS (holes) in the laminate.

  8. Lamination process • Composite lamination process has mainly 2 technical desires. • The fibers are clean and neatly placed in the direction where the forces act • The resin matrix is applied to the fibers such the ALL FIBERS are WETTED with the minimum amount of resin and with ZERO VOID CONTENT. • The fiber volume fraction is to be as high as possible and any means technically applicable are to be used to get the VOLUME FRACTION preferably .

  9. Composite market in Finland • The market is small and export oriented. • There are 3 big market section in Finland( Boats, Aircraft, chemical industry) • NCE Oy (chemically corrosion resistant materials for heavy industry) • Nautor Swan and Baltic yachts, marine super yacht construction, low mass and sea water tolerant • Kesko marine, marine mass producer, motor speed boats, sea water resistant and some low mass issues • Air craft part manufacturing (Airbus A 380 spoilers, Patria Oy, low mass)

  10. Future composite market in Finland • The marine lamination capacity in Finland is large and high tech and suffers of economic down turn. • Vihicle sector (trucks and train parts) is starting to establish itself (small scale) • Chemical sector is expanding • Sports equipment on small scale is coming (wake bord, kite bord, skis) • Wind turbine market is coming but very competitive • Aircraft market is small and remains marginal

  11. Self study (3h, no report but all questioin do come in exam ) • What is glue and what is resin? • What is the difference between polyester, vinylester and expoxy (table with (strength, strain, chemical and thermal stability, price, viscosity)? • How is resin setting (geltime, barcol hardness, post cureing)? • What is hand lamination, vacuum infusion, vacuum bagging and auto clave lamination? • Which fiber volume fractions can be reached with above methods?

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