PPT - Materials Education

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 industries
! Electrical & electronicsstandoffs, circuit boards, junction
boxes, ladder rails, cherry picker
buckets
! Corrosion resistant
systems- oil field pipes, pump
bodies, suction rods
! Appliances & equipmentcompressor bases, washing
machine gears and parts, power
tool housings, computer housings
! Renewable Energy
systems- wind, ocean, solar
Composite pros & cons
! advantages
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
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workforce trained in composite usage
work experience using composites
design experience with composites
repair experience with composites
!  Students needs
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hands on experience with composites
Students who want to work in growing
advanced composite industries
Design experience using composites
!  College needs
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New technologies for students
New courses for program development
New laboratory ideas & equipment
Internships and industry partnerships
Lay-Up with splice
Industry connections
! Training for new employees and
educational upgrades
! Internships for students and
faculty
! Research ideas for faculty and
students
! Industry tours for processing
classes
! Projects for capstone classes and
senior projects
! Feedback from employed alumni
! Development of training programs
! Equipment and lab material
donations
! Expertise for developing
programs and ideas
Industry ideas
! Review product, processes.
Materials, inspection and repair
techniques
• Cessna
• Monaco and Country Coach
• ECS Case
• Bayliner
• Boeing
• Erickson Air Crane
! Tooling
! Lean
! GD&T
! Six sigma
! CAD/CAM
! Automated systems
! Communication skills
! Material conveyance
! Repair
! Testing and Inspection
Course Outline
! Introduction to composites
! Advanced composites ( high temp/
high performance)
! Environmental effects on composites
! Fiber reinforcements
! Composite design considerations
! Tooling
! Inspection and testing
! Adhesive bonding
! Advanced composite assembly
! Liquid molding
! Industries and processes using
advanced composites
! Repair of composites
! Nanocomposites
Laboratory Development
Laboratory experiments
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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
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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 DEFECTS
DEFECT
Bubbles
Wrinkles
Loose Fibers
Resin Starved Areas
Resin Rich Areas
Ply Orientation
Porosity
Surface Defects
Inclusions
Fiber Distortion
Voids
Contamination
FOD - FOE
Burned Resin
Burned Bag
Vacuum Leak
Delamination
Ply Gaps
TC Problems
Bridging
De-Bonds
Damaged Plies
Micro Cracking
Matrix (resin) Concerns
Uncured Resin
Warped Laminate
Blown Bag
LAY-UP
SEQUENCE
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BAGGING
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FIBERS
RESIN
CURE
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TOOL
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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)
Panel or Test Cupon (A)
60.Test
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Hose
61. Vacuum
____________________
(B)
B
C
Probes
62. Vacuum
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(C)
Gage
63.Vacuum
____________________
(D)
Wire
64.T.C.
____________________
(E)
D
E
(example B )
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 time
D. None of the above
CIRCLE THE CORRECT ANSWER:
66. Preimpregnated cloth may be warmed to provide greater flexibility when laying
up parts.
A. True
B. False
Page 10
72. From (Figure 1) below identify item #4.
Nylon bag
#4. __________________________
73. From (Figure 1) below identify item # 1.
Tool Plate
#1. __________________________
74. From (Figure 1) below identify item # 3.
Breather
#3. __________________________
75. From (Figure 1) below identify item # 7.
TC wire
#7. __________________________
(Figure 1)
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Simulated Part
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flash-breaker tape
1
(1)
(2) Simulated Project Part (use cardboard)
(3)
(4)
(5) Sealant Tape
(6) Vacuum Probe (through the bag)
(7)
© Robert N. Young
Rev. 1/21/06
All Rights Reserved
Page 12
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
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‘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’