Presentation is loading. Please wait.

Presentation is loading. Please wait.

Introduction to Advanced Composite Materials

Similar presentations

Presentation on theme: "Introduction to Advanced Composite Materials"— Presentation transcript:

1 Introduction to Advanced Composite Materials
Global Hawk UAV

2 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 aircraft applications ceramic & metal matrix materials repair techniques

3 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

4 Other industries Electrical & 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

5 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

6 Course Development Industry needs Students needs College needs
Lay-Up with splice 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

7 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

8 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

9 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

10 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

11 Lab Equipment Benches Freezer Vacuum pump Hand tools Safety equipment
Furnace/autoclave thermocouples

12 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

13 Lab Material Woven material –fiberglass, carbon fiber & aramid
Resin fast and slow Vac bagging materials Mixing materials

14 Lab Wet hand lay up Bagging/Debulking

15 Composite Inspection Methods
Visual Delamination

LAY-UP SEQUENCE DEFECT BAGGING FIBERS RESIN CURE TOOL Bubbles Wrinkles Loose Fibers Resin Starved 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 Blown Bag Resin Rich Areas Warped Laminate X

17 Course assessments Testing & Homework Ply orientations
Conventional testing but with problems that are specifically applicable to composite industry problems. Homework & research based on composite industry problems.

18 B Test Panel or Test Cupon 60. ____________________ (A) Vacuum Hose
IDENTIFY AND NAME THE COMPONENTS INDICATED BELOW (A THROUGH E) C D E B Test Panel or Test Cupon 60. ____________________ (A) 61. ____________________ (B) Vacuum Hose Vacuum Probes 62. ____________________ (C) Vacuum Gage 63. ____________________ (D) T.C. Wire 64. ____________________ (E) CIRCLE THE CORRECT ANSWER: (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 66. Preimpregnated cloth may be warmed to provide greater flexibility when laying up parts. A. True B. False Page 10

19 (Figure 1) 72. From (Figure 1) below identify item #4. Nylon bag
#4. __________________________ Nylon bag 73. From (Figure 1) below identify item # 1. #1. __________________________ Tool Plate 74. From (Figure 1) below identify item # 3. #3. __________________________ Breather 75. From (Figure 1) below identify item # 7. #7. __________________________ TC wire (Figure 1) 6 4 3 5 7 Simulated Part 2 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

20 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

21 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’

Download ppt "Introduction to Advanced Composite Materials"

Similar presentations

Ads by Google