1. D AY 35: M AKING C OMPOSITE M ATERIALS Some Matrix Materials Manufacturing Methods Structural Composites

2. B OEING 767

3. A IRBUS A380 http://www.airporttech.tc.faa.gov/safety/patterson2.asp

5. http://www.hsc.csu.edu.au/engineering_studies/aero_eng/2579/polymer_composites.html

6. C OMPOSITE P ROPERTIES (E POXY M ATRIX ) V F =0.6

7. B ORON F IBERS ARE AN UNCOMMON ADDITION – T HEY ARE LARGE AND INFLEXIBLE http://www.metallographic.com/Procedures/Applications.htm Epoxy Boron Graphite

8. B ORON F IBER - C HEMICAL V APOR D EPOSITION ON A T UNGSTEN W IRE http://www.specmaterials.com/boronfiber.htm

9. C ARBON F IBER (H EXCEL ) http://www.hexcel.com/NR/rdonlyres/225E3CA5-965B-4B29-9A92- 0CE184B1DDF3/0/CarbonFiber_SelectorGuide.pdf

10. C ARBON F IBERS (T ORAY ) http://www.toraycfa.com/pdfs/Torayca SummaryDataSheet.pdf

12. http://www.fibraplex.com/tow.asp

13. C ARBON E POXY C OMPOSITE P ROPERTIES http://www.hexcel.com/NR/rdonlyres/225E3CA5-965B-4B29-9A92- 0CE184B1DDF3/0/CarbonFiber_SelectorGuide.pdf

14. C OST C OMPARISON

15. M ATRIX M ATERIALS FOR C OMPOSITES Function and Properties of the Matrix Material 1. Binding fibers together into a shape 2. Protect the fibers from damage 3. Serve as a barrier to failure. If an individual fiber fails, the failure will not spread. 4. Be very easy to bond to fiber The matrix materials are usually polymers and are the”weak link” as far as operating temperatures are concerned.

16. L IST OF M ATRIX M ATERIALS, SOMETIMES CALLED “ RESINS ” Polyester Vinyl ester Epoxy Phenolic PEEK

17. P OLYESTER Very common polymer family. It can be thermoplastic and in this form is a common synthetic fiber. Unsaturated polyesters are used in producing thermosets, (copoymerization with styrene) which are used as matrix materials. Mostly in fiberglass. The bond is strong, and is particularly good at resisting water and chemical attack. Cheap

18. V INYL E STERS Better than polyester, but a little more expensive. Gives upper end fiberglass. Glassair – first composite kit airplane.

19. E POXY We have already discussed this one, a top of the line thermoset, very commonly used in aerospace composites.

20. O THERS Phenolics, high strength thermosets. Very good adhesives and high temperature uses. PEEK. PEI (polyetherimide) PPS (polyphynolene sulfide) Very strong. Good at higher temperatures. This is a thermoplastic. In recent years, thermoplastic matrix materials have seen increased use. Tough, damage resistant, can be welded!

21. F ABRICATION P ROCESSES Pultrusion Filament winding Prepreg and Lay up

22. P ULTRUSION Quick, inexpensive way to make long fiber oriented composites. Fibers oriented. For the kind of stuff you make by extrusion. Hollow core is possible.

23. P ULTRUSION I MAGES http://www.henanpolymer.com/english/frp1.html http://www.aims-intl.com/images/grating___pultruded.gif

24. F ILAMENT W INDING Filaments are carefully wound onto a mandrel after being wetted with resin. When the desired number of windings is obtained, the object may be cured. The manufactured object will often be cylindrical in shape.

25. F ILAMENT W INDING I MAGES http://www.gilgwang.com/english/frp/img/grp03.gif http://imghost.indiamart.com/data/T/P/MY-718936/filament- wound-frp-pipes_10676686_250x250.jpg http://www.adoptech.com/pressure-vessels/main.htm

26. P REPREG AND L AYUP You will see sheets of prepreg. They consist of the fiber and the uncured resin, with paper backing. The sheets are applied, often by hand to a form, where they adhere. This is often done by hand, by expert workers. Then cure.

27. I MAGES Prepreg must be stored at low temp. to avoid curing or drying out.

28. C OMPOSITE MADE BY LAY UP

29. S TRUCTURAL C OMPOSITES Sandwich Composites are an example of how different parts of a beam, plate or shell structure can be made in layers, in which each layer performs a function.

30. S ANDWICH

31. T YPES OF H ONEYCOMB Aramid Fiber (Nomex®/Kevlar®) Aluminum Stainless Steel Thermoplastic Polycarbonate Polypropylene PVC SAN PE ABS http://www.plascore.com/product-honeycomb-cores.htm?gclid=CJK_5_HP6p8CFQoNDQodExVGYg

32. http://www.azom.com/details.asp?ArticleID=1092#_Honeycombs

33. A PPLICATION : T OYOTA E AGLE 987 Fuselage is carbon fiber honeycomb composite

34. GLARE GLARE is used in aerospace structures. It is a composite in which layers of aluminum and fiberglass prepreg sheets are bonded together by epoxy. Why not use carbon fiber? The fibers are aligned in a way which is most favorable for load carrying. Once fabricated, GLARE is then processed in much the same way that aerospace aluminum is.

35. GLARE I MAGES (H YBRID C OMPOSITE ) Outer layers of Aluminum act as protective barriers. Water absorption can be a problem. Here is reduced

36. USE OF GLARE