advanced composites from joe stuart ppt

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Introduction to Advanced Composite Materials Global Hawk UAV

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Page 1: Advanced Composites From Joe Stuart PPT

Introduction to Advanced Composite Materials

Global Hawk UAV

Page 2: Advanced Composites From Joe Stuart PPT

An introduction to composites:

modern composites definedmatrix of resin +fiber

advanced composites> strength : weight ratiospecific purpose design

composite history & evolution60 yrs of accelerating advancesfiberglassepoxy matrixcarbon fiberaramid fibersadvanced composites

aircraft applicationsceramic & metal matrix materialsrepair techniques

Page 3: Advanced Composites From Joe Stuart PPT

Composite applicationsTransportationGround, air, marine, space

Militaryarmor, weapons, containers

Sporting goodsgolf, tennis, fishing, helmets, wheels, skis/snow boards, kite and wind surfing, snow machines, gun components

Building materialspipes, beams, panels, bridges, roofing, decking, signs, furniture

Medicalprosthetic devices, braces, enclosures, body moving aids

Page 4: Advanced Composites From Joe Stuart PPT

Other industriesElectrical & electronics-

standoffs, circuit boards, junction boxes, ladder rails, cherry picker buckets

Corrosion resistant systems- oil field pipes, pump bodies, suction rods

Appliances & equipment-compressor bases, washing machine gears and parts, power tool housings, computer housings

Renewable Energy systems- wind, ocean, solar

Page 5: Advanced Composites From Joe Stuart PPT

Composite pros & consadvantages stiffness, TS/p, high fatigue life, corrosion resistant, complex shapes, smooth skin, stealth, multiple mfg methods

Disadvantageshigh labor, material and capital costs,storage of materialsdamage and repairssafety concerns

Page 6: Advanced Composites From Joe Stuart PPT

Course Development

Industry needs• workforce trained in composite usage• work experience using composites• design experience with composites• repair experience with composites

Students needs • hands on experience with composites• Students who want to work in growing

advanced composite industries• Design experience using composites

College needs • New technologies for students• New courses for program development• New laboratory ideas & equipment• Internships and industry partnerships

Lay-Up with splice

Page 7: Advanced Composites From Joe Stuart PPT

Industry connectionsTraining for new employees and

educational upgradesInternships for students and

facultyResearch ideas for faculty and

studentsIndustry tours for processing

classesProjects for capstone classes and

senior projectsFeedback from employed alumniDevelopment of training programs Equipment and lab material

donationsExpertise for developing

programs and ideas

Page 8: Advanced Composites From Joe Stuart PPT

Industry ideasReview product, processes.

Materials, inspection and repair techniques•Cessna•Monaco and Country Coach•ECS Case•Bayliner•Boeing•Erickson Air Crane

Tooling Lean GD&TSix sigmaCAD/CAMAutomated systemsCommunication skillsMaterial conveyanceRepairTesting and Inspection

Page 9: Advanced Composites From Joe Stuart PPT

Course OutlineIntroduction to compositesAdvanced composites ( high

temp/high performance) Environmental effects on

compositesFiber reinforcementsComposite design considerationsToolingInspection and testingAdhesive bondingAdvanced composite assemblyLiquid moldingIndustries and processes using

advanced compositesRepair of compositesNanocomposites

Page 10: Advanced Composites From Joe Stuart PPT

Laboratory Development

Laboratory experiments• Wet lay up-flat• Build a clip board• Build a mold & mold prep• Wet lay up with clocking in a

mold• Prepreg layup with clocking in

mold• De-bulking vac bag • Make a product (skate board

or surf board)• Resin transfer molding

experiment

Page 11: Advanced Composites From Joe Stuart PPT

Lab Equipment

• Benches• Freezer• Vacuum pump • Hand tools• Safety equipment• Furnace/autoclave• thermocouples

Page 12: Advanced Composites From Joe Stuart PPT

Safety

• Identify safety hazards and hazardous waste

• Illustrate use of safety equipment

• Encourage compliance of safety regulations

• List personal protective equipment

• Post Material Safety Data Sheets

• Location and use of fire extinguishers

Page 13: Advanced Composites From Joe Stuart PPT

Lab Material

• Woven material –fiberglass, carbon fiber & aramid

• Resin fast and slow• Vac bagging materials• Mixing materials

Page 14: Advanced Composites From Joe Stuart PPT

Lab

Wet hand lay up Bagging/Debulking

Page 15: Advanced Composites From Joe Stuart PPT

Composite Inspection Methods

Visual Delamination

Page 16: Advanced Composites From Joe Stuart PPT

• VISUAL INSPECTION DEFECTSDEFECT LAY-UP

SEQUENCEBAGGING FIBERS RESIN CURE TOOL

BubblesWrinklesLoose FibersResin Starved Areas

Ply OrientationPorositySurface DefectsInclusionsFiber DistortionVoidsContaminationFOD - FOEBurned ResinBurned BagVacuum LeakDelaminationPly GapsTC ProblemsBridgingDe-BondsDamaged PliesMicro CrackingMatrix (resin) ConcernsUncured Resin

Blown Bag

Resin Rich Areas

Warped Laminate

X X XX X XX XX X XX X XX X XX XXX X XX X XXX XX X XX X XX XX X XX X

X XX

X X X XXX XX X X

X XX XX

X X X

X XXX X XX X

X X

Page 17: Advanced Composites From Joe Stuart PPT

Course assessments

Testing & Homework• Conventional testing but

with problems that are specifically applicable to composite industry problems.

• Homework & research based on composite industry problems.

Ply orientations

Page 18: Advanced Composites From Joe Stuart PPT

IDENTIFY AND NAME THE COMPONENTS INDICATED BELOW (A THROUGH E)

60. ____________________ (A)61. ____________________ (B)

62. ____________________ (C)63. ____________________ (D)64. ____________________ (E)

66. Preimpregnated cloth may be warmed to provide greater flexibility when layingup parts.

A. True B. False

65. The temperature hold period at 240 +/- 100F is intended to:A. Cure the laminate.B. Raise the viscosity of the resin so that it will no longer flow.C. Allow for break timeD. None of the above

Test Panel or Test CuponVacuum Hose

Vacuum ProbesVacuum GageT.C. Wire

CIRCLE THE CORRECT ANSWER: (example B )

Page 10

C

DE

B

Page 19: Advanced Composites From Joe Stuart PPT

72. From (Figure 1) below identify item #4. #4. __________________________

73. From (Figure 1) below identify item # 1.#1. __________________________

Nylon bag

Tool Plate

74. From (Figure 1) below identify item # 3.#3. __________________________ Breather

75. From (Figure 1) below identify item # 7.#7. __________________________ TC wire

Page 12

(Figure 1)

(1) (2) Simulated Project Part (use cardboard)(3) (4) (5) Sealant Tape(6) Vacuum Probe (through the bag)(7)

4

2

1

56

37

Simulated Partflash-breaker tape

© Robert N. YoungRev. 1/21/06

All Rights Reserved

Page 20: Advanced Composites From Joe Stuart PPT

Team Projects

Projects• Develop drawing sets specific

to advanced composite parts and assemblies

• Develop a composite product through design and lay out its manufacturing sequences and then cost the product

• Graded via peer evaluations in presentation

Page 21: Advanced Composites From Joe Stuart PPT

References• ‘Manufacturing Processes for Advanced Composites’ by F. C. Campbell,

Elsevier• ‘Advanced composite stuctures: fabrication and damage repair’ Abaris

Training Resources Inc. • ‘Materials Science and Engineering an Introduction’ by William D. Callister,

Jr. 7th ed., Wiley• Cessna Training program Bend, OR• ‘Mechanics of Composite Materials’ by Autar K. Kaw 2nd Edition CRC Taylor

and Francis Group• ‘Materials Selection In Mechanical Design’ by Michael F. Ashby 3rd ed.,

Elsevier• CRC Practical Handbook of Materials Selection by James Shackelford,

William Alexander & Jun S. Park• Abaris Training-’Advanced Composite Structures: Fabrication and Repair’• Cerritos College ‘Composite Lay-Up Manual’