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’