P10229: Composites Autoclave Brian Cario: ME Matt Brady: ME Matt DiFrancesco: ME Brandon Allen: EE John Mink: EE

Preliminary Design Review Agenda Project Background Project Objectives Benchmark Potential Users Customer Requirements Engineering Specifications Project Schedule Work Breakdown Concept Screening and Selection System Function Risk Mitigation Design Feasibility Studies Preliminary Project Budget Next Steps 2

Background: Purpose of an Autoclave Device for Curing Components Made of Composite Materials Under Heat and Pressure High-Strength, Low Mass Very Low Void Ratio 10x Wet Layup 3 Image Courtesy directindustry.com

Project Objectives Senior Design 1 Senior Design 2 Tasks   Senior Design 1 Senior Design 2 Tasks Concept Generation and Selection Complete Pressure Vessel Construction Detailed Design, Ready for Construction Test Pressure Vessel Spec Stock Parts Final Assembly Test Autoclave Deliverables Complete Autoclave Design Complete, Operable Autoclave Partially Built Pressure Vessel Manual for Operation Some Parts Obtained 4

Benchmark: ASC Process Systems Econoclave 22” Dia x 48” Long Working Volume 200psig Max Pressure 500oF Max Temperature 5oF Temp Uniformity PC User Interface Electric Heat Extensive Safety Systems Fast-Closing Door Priced from $85k-$120k plus delivery and setup 5

Potential Users of an Autoclave at RIT MET Department--Student Projects Proposed location: Composites Lab Student Teams: Baja, Formula, Aero ME Department for Research CIMS Future Senior Design Groups Anyone Needing a super lightweight structure Possible Outside Users Future, Unforeseen Uses 6

Why Have an Autoclave at RIT? Strong lightweight components are becoming increasingly important Rented Autoclave Time is Rare and Expensive Production-Scale Utility Bills can reach $750/run On-Site Option Offers Convenience Could be Customized for Other Future Uses Learning Tool Enables Ongoing, Long-Term Research Renting Time Could Generate Funding 7

Customer Requirements Customer Need # Importance Description Comments/Status CN1 1 The pressure vessel can safely hold 150 psi @ 400F Pressure vessel will by hydrostatically tested to 300 psi CN2 Heating system can reach and maintain a temperature of 400F   CN3 The autoclave operates on 440 VAC or 220 VAC CN4 The autoclave is protected from over pressurization and over heating CN5 The autoclave is accompanied by an operations manual CN6 The pressure vessel has fittings for an external vacuum pump CN7 The autoclave has safety signage CN8 2 The pressure vessel has a door sized the entire cross sectional area of the chamber CN9 The user interface directly controls pressure, temperature (ramp rates, cooling) CN10 The user interface displays pressure and temperature in real time CN11 The pressure vessel is capable of holding a vacuum CN12 The pressure vessel is thermally insulated CN13 The autoclave has a uniform internal temperature This will be done with a blower CN14 3 The pressure vessel interior is 3' in diameter and 4' deep This is very budget depending CN15 The autoclave is portable Pressure vessels are usually very heavy so portability is not feasible CN16 The autoclave has plumbing for integrated cooling system 8

Specification or Metric Engineering Specifications Metric Need Specification or Metric Imp. Units Marginal Value Ideal Value 1 1,6 Emergency Pressure Relief psi MAOP +60 MAOP +30 2 Max Operating Temperature Deg F 250 400 3 6 Emergency Shut off Temperature MAOT +100 MAOT +50 4 16 Delta Chamber Cut off Temperature +/- 75 +/- 50 5 ASME,1 Certification Pressure 1.5 * MAOP 2 * MAOP Max Operating Pressure 35 120 7 Temperature Ramp Rates Deg F/min 10 8 Temperature Resolution 9 Pressure Resolution Interior Diameter ft 11 Interior Length 12 Supply Voltage VAC 440 220 13 Autoclave Weight lbs 6000 1000 14 Max External Operating Temp 300 100 9

Project Schedule and Gantt Chart 10

Summarized MSD 1 Timeline Week 1 Background and research autoclave functionality. Team Organization Week 2 Interview potential customers Develop engineering specifications Week 3 Concept generation and selection Risk management Future Scheduling Week 4 Determine design feasibility Prepare for Preliminary Design Review Week 5 Prepare preliminary design review Weeks 6-8 Detail design generation Spec stock components Finalize Budget Week 8 Begin Pressure vessel construction Week 9 Generate Bill of Materials Begin preparation for Final Design Review Week 10 Prepare for Final Design Review

Concept Screening Matrix: Pressure Vessel   A B C D E F (Reference) Selection Criteria Fabricated Non-Certified Vessel Cast Iron Pipe and Flanges High-Pressure Water Tank ASME Certified (Econoclave) Used Certified Vessel Square Vessel Instead of Cylindrical Cost + Ease of Manufacture - Ease of Integration of I/O Ports Ease of Adding Door Pressure Capability Safety Certification Needs Weight Portability Ease of Heating Sum + 's 4 1 2 Sum 0's 10 9 3 Sum -'s 7 6 Net Score 0.00 -6.00 -5.00 1.00 Rank T2 T4 Continue? Yes No 12

Weighted Concept Selection Matrix    A B C  D E (Reference) Fabricated Non-Certified Vessel Cast Iron Pipe and Flanges High Pressure Water Tank ASME Certified (Econoclave) Used Certified Vessel Square Instead of Cylindrical Selection Criteria Weight Rating Wtd Cost 20% 5 1 3 0.6 4 0.8 Ease of Manufacture 10% 2 0.2 0.3 Ease of Integration of I/O Ports 7% 0.14 0.07 0.21 Ease of Adding Door 0.1 Pressure Capability 8% 0.08 0.24 Safety 15% 0.15 0.45 Certification Needs 3% 0.12 0.06 0.09 Portability 2% 0.02 0.04 Ease of Heating  0.30  0.10 Total Score 3.19 2.63  2.31 3.18 2.3 Rank 6 Continue?  Yes No Yes 13

System Function 14

System-Level Risk Mitigation 15

Pressure Vessel Feasibility Based on a 24” Diameter, 5-foot long Pressure Vessel Constructed of 0.250” Wall Grade-B Pipe, Caps, and Flanges Yield Pressure is Limited by Hoop Stress in the Cylindrical Portion of the Vessel to 729.17psi This is 3.86 times out maximum operating pressure of 150psi 16

Insulation Feasibility 0.4m Outer Radius Corresponds to a 3.5” Thick Layer of Insulation Using Common R13 Fiberglass this gives an Outer Surface Temp of 80F 17

Heating System Feasibility Total power to maintain max. temp: ~470W Total power to heat up air at 15F/min (total 27 min): ~1.5kW Allowing for thermal mass of parts/molds/pipe, ~4-5 kW needed Can easily be run on available 240V power Elements of this size commonly available Blower inside vessel will help maintain uniform temp. 18

Initial Cyl Pressure (psi) Final Cyl Pressure (psi) Pressurization Feasibility Run Number Initial Cyl Pressure (psi) Run Pressure (psi) Final Cyl Pressure (psi) 1 2000 MAX 124.34 60 1094.915254 2 189.8305085 15 1773.728814 1547.457627 3 1321.186441 4 5 868.6440678 6 642.3728814 7 416.1016949 8 Assumes Use of Standard AL-size (9”x53” nom.) Gas Cylinder Filled with Gaseous Nitrogen One Bottle good for one full pressure run of 124psi or several runs at reduced pressure. 19

Preliminary Electrical Design 240VAC Supply Stepped down to 120VAC and 12VDC as needed Electrical Pressure Control for Good Precision, Added Safety Electrical (PID) Heating Control including control of Ramp Rates External Electrical Layout 20

Bulkhead Connector Pressure tested to 2000psi Available with multiple wire combinations 9-wire, 22awg connector will work for our application Image © www.pavetechnologyco.com

Electrical Load Heater ~ 5kW @ 220V, approximately 23A Blower ~ ½ hp = 372.85W @ 220V, approximately 1.7A Computer ~ 300W @ 110V, approximately 3A DC Power supply ~ 1kW about 10A Pressure Regulator ~ 50mA at 12V 220V – 110V Transformer ~ 1kW, approximately 5A

Control System Feasibility 23

Preliminary Safety System Plan MSDS for potential resin systems External Signage Extensive Operations Manual Door Proximity Switch Over-pressure Blow-Off Valve Exhaust Routed into existing Fume Hood Thermal Fuse All Relays and Solenoid Valves Default to Safe Software Able to Detect Unsafe Conditions Emergency Stop Button 24

Estimated Initial Budget Pressure Vessel   2' Diameter x 5' Long Pipe 1 N/A Donated 24" Outer Diameter Tank End Cap 2 445.28 890.56 32" Outer Diameter 1.88" Thick Flange 650.08 1300.16 2" x 2" x .25 " Angle Steel 40' 9.00 per 4' 90 24" x 48" x 3/16 Sheet Steel 45 5" Diameter Swivel Caster 4 14.99 59.96 1"-14 x 5" Grade 5 Bolts 20 17.18 for 5 68.72 1"-14 Grade 5 Nuts 6.25 for 10 12.5 2' x 2' x 3/4" Steel Plate for Hinge Fabrication 203.76 Miscellaneous Other Tank Hardware Labor for Tank Machining and Welding 10 Hours 100/hr 1000 Subsystem Total 3690.66 Pressurization Nitrogen Regulator 150 Input Solenoid Valve 75 Dump Solenoid Valve 85 Pipe/Hose/Fittings misc. 385 Heating, Insulation, Circulation R13 Insulation 63 ft^2 5kW Incoloy Heating Element 250 Sheetmetal Shell 125 Blower Motor 100 Squirrel Cage Blower 15 Hi Temp Hi Pressure Shaft Seal 30 60 570 Electrical 250C Rated Wire 100ft 30/50ft Standard THHN Wire 15/50ft 1/2" Sealtite Conduit 50ft 50/100ft 50 PaveTechnologies Bulkhead Connector 135  270 410 Controls Thermocouple 5 25 Pressure Transducer Control Board 365 Total $5420.70 Estimated Initial Budget 25

Commitments to Date $2000 from KGCOE Multidisciplinary Senior Design Pipe and Potential Labor Donated by Rochester Gas and Electric – estimated value = $1500+ 15hr/week x 5 team members x 22 weeks = 1650 hours x $85/hr = $140k+ in Free Design Time from the P10229 Team 26

Next Steps Procure Funding – by 1-29-10 Complete Detailed Design Failure Mode Analysis FEA on Pressure Vessel, Stand Begin Pressure Vessel Fabrication Spec Stock Parts Simulate Controls and Software Solidify exact heating requirements 27

Heating Concept Screening Matrix   A B C D (Reference) Selection Criteria Static Incoloy Heating Elements (no circulation) Nichrome Wire External Gas Burner/Heat Exchanger Convection Incoloy Tubular Heating Elements Manufacturing Cost + - Ease of Manufacture Response Time Ease of Control Pressure Capability Safety Infastructure Needs Operating Cost Portability Temperature Uniformity Sum + 's 2 1 Sum 0's 4 7 10 Sum -'s Net Score -2.00 -1.00 -6.00 0.00 Rank 3 Continue? No Yes

Heating Weighted Concept Selection   A B C D Static Incoloy Heating Elements (no circulation) Nichrome Wire External Gas Burner/Heat Exchanger (Reference) Convection Incoloy Tubular Heating Elements Segment Selection Criteria Weight Rating Notes Wtd Manufacturing Cost 15% 4 0.60 1 0.15 3 0.45 Ease of Manufacture Response Time 2 0.30 Ease of Control 8% 0.08 0.24 Pressure Capability 10% 0.20 Safety 0.10 Infastructure Needs Operating Cost 5% Portability 2% 0.06 0.02 Temperature Uniformity Total Score 2.69 2.90 1.75 3.00 Rank Continue? No Yes

Pressurization Concept Screening Matrix   A B C D (Reference) Selection Criteria Shop Air with Accumulator Shop Air Bottled Gaseous Nitrogen On-board Compressor Manufacturing Cost - + Ease of Manufacture Temperature Stability Operating Cost Pressure Capability Safety Certification Needs Weight Portability Strain on Infastructure Pressurization Rate Sum + 's 1 3 6 Sum 0's 4 5 11 Sum -'s Net Score -5.00 0.00 5.00 Rank T2 Continue? No Yes

Pressurization Weighted Concept Selection   A B C D Shop Air with Accumulator Shop Air Bottled Gaseous Nitrogen (Reference) On-board Compressor Segment Selection Criteria Weight Rating Notes Wtd Manufacturing Cost 9% 2 0.18 5 0.45 3 0.27 Ease of Manufacture 4 0.36 Temperature Stability 15% 0.75 Operating Cost Pressure Capability 0.30 Safety 10% Certification Needs 1 0.09 3% 0.06 0.15 0.12 Portability 2% 0.02 0.04 Strain on Infastructure 0.10 Pressurization Rate Total Score 2.69 2.96 4.08 3.00 Rank Continue? No Yes

Controls Concept Selection Matrix   A B C D (Reference) Selection Criteria On/Off (no adjustability) Knobs and Dials PID Control Computer Interfaced Manufacturing Cost + Ease of Manufacture Ease of Operation - Temperature Control Feedback Programmability Safety Controls Weight Portability Sum + 's 5 4 Sum 0's 1 3 9 Sum -'s 2 Net Score 1.00 0.00 2.00 Rank T3 Continue? Yes

Controls Weighted Concept Selection   A B C D On/Off (no adjustability) Knobs and Dials PID Control (Reference) Computer Interfaced Segment Selection Criteria Weight Rating Notes Wtd Manufacturing Cost 5% 5 0.25 4 0.20 3 0.15 Ease of Manufacture 10% 0.50 0.40 0.30 Ease of Operation 18% 0.72 0.54 2 0.36 Temperature Control 1 0.18 Feedback 15% 0.45 Programmability Safety Controls 2% 0.10 0.06 Portability Total Score 2.30 2.20 2.90 3.00 Rank Continue? No Yes

Resin System MSDS http://www.westsystem.com/ss/assets/MSDS/MSDS105.pdf http://www.westsystem.com/ss/assets/MSDS/MSDS205.pdf