Introduction to Advanced Composite Materials
Global Hawk UAV
An introduction to composites: modern composites defined
matrix of resin +fiber
advanced composites
> strength : weight ratio
specific purpose design
composite history & evolution
60 yrs of accelerating advances
fiberglass
epoxy matrix
carbon fiber
aramid fibers
advanced composites
aircraft applications
ceramic & metal matrix materials
repair techniques
Composite applications Transportation
Ground, air, marine, space
Military
armor, weapons, containers
Sporting goods
golf, tennis, fishing, helmets, wheels, skis/snow boards, kite and wind surfing, snow machines, gun components
Building materials
pipes, beams, panels, bridges, roofing, decking, signs, furniture
Medical
prosthetic devices, braces, enclosures, body moving aids
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
Composite pros & consadvantages
stiffness, TS/p, high fatigue life,
corrosion resistant,
complex shapes,
smooth skin, stealth,
multiple mfg methods
Disadvantages
high labor, material and capital
costs,
storage of materials
damage and repairs
safety concerns
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
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Lay-Up with splice
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
Industry ideasReview product, processes. Materials, inspection and repair techniques
•Cessna
•Monaco and Country Coach
•ECS Case
•Bayliner
•Boeing
•Erickson Air CraneTooling Lean GD&TSix sigmaCAD/CAMAutomated systemsCommunication skillsMaterial conveyanceRepairTesting and Inspection
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
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
Lab Equipment
• Benches• Freezer• Vacuum pump • Hand tools• Safety equipment• Furnace/autoclave• thermocouples
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
Lab Material
• Woven material –fiberglass, carbon fiber & aramid
• Resin fast and slow• Vac bagging materials• Mixing materials
Lab
Wet hand lay up Bagging/Debulking
Composite Inspection Methods
Visual Delamination
• 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
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
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 laying up 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 Cupon
Vacuum Hose
Vacuum Probes
Vacuum Gage
T.C. Wire
CIRCLE THE CORRECT ANSWER: (example B )
Page 10
C
D
E
B
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
5
63
7Simulated Part
flash-breaker tape
© Robert N. YoungRev. 1/21/06
All Rights Reserved
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
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’