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Introduction to Advanced Composite Materials Global Hawk UAV.

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Presentation on theme: "Introduction to Advanced Composite Materials Global Hawk UAV."— 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 advanced composites 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 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

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 upBagging/Debulking

15 Composite Inspection Methods Visual Delamination

16 VISUAL INSPECTION DEFECTS DEFECT LAY-UP SEQUENCE BAGGINGFIBERSRESIN 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 XXX XXX XX XXX XXX XXX XXX XX X XXX X X X XXX XXXXX XXXXX XX X XXXX X XX XXX XX XXX XXX XX X XXX XX XX

17 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

18 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. TrueB. False 65. The temperature hold period at 240 +/- 10 0 F 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 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

19 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 6 3 7 Simulated Part flash-breaker tape © Robert N. Young Rev. 1/21/06 All Rights Reserved

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. 7 th ed., Wiley Cessna Training program Bend, OR ‘Mechanics of Composite Materials’ by Autar K. Kaw 2 nd Edition CRC Taylor and Francis Group ‘Materials Selection In Mechanical Design’ by Michael F. Ashby 3 rd 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’

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