1. Composite Materials Bill Pedersen

2. Components of Polymer Composites Polymer Resin Usually a thermoset Usually a thermosetEpoxyPolyesterVinylester Thermoplastics - Aerospace Thermoplastics - Aerospace Reinforcing fiber Fiberglass Fiberglass E, S, C (E most common) Graphite (Carbon) Graphite (Carbon) Aramid (Kevlar) Aramid (Kevlar) Spectra (PE) Spectra (PE)

3. Open Molding Female Mold of part Made of FRP (Fiberglass Reinforced Polymer) Made of FRP (Fiberglass Reinforced Polymer) Has steel supports Has steel supports Gel coated and waxed Gel coated and waxed To make part: Gel coat mold Gel coat mold Spray on chop fibers, resin and catalyst Spray on chop fibers, resin and catalyst Roll out air Roll out air Add stiffeners or layers as desired Add stiffeners or layers as desired

4. Vacuum Bagging Greatly reduced VOC (Volatile Organic Content) (Reduced emissions) Cover reinforcement with cheap plastic cover Suck resin into the part to fill the void

5. Making a Kayak

7. Open vs. Closed Molding Open Molding As shown previously As shown previously Only one sided mold Only one sided mold Limited temperature control Limited temperature control Lower capital cost for molds Lower capital cost for molds Closed molding – or compression molding Two sided mold – part is sandwiched between two mold halves Pressure applied Improved material properties (fewer voids) Higher Capital cost

8. Closed Molding Can be done using Pre- preg or wet layup Process: Resin impregnated fibers cut to proper geometry Resin impregnated fibers cut to proper geometry Heated Die sets close on part Heated Die sets close on part Part is cured at temperature Part is cured at temperature Die opens and part is ejected from mold Die opens and part is ejected from mold

9. Filament Winding Control the orientation of the fiber using a relative motion of rotation and linear motion Example Products: Pressure Vessels Pressure Vessels Fishing Poles Fishing Poles Light Poles Light Poles Antennas Antennas

10. Pultrusion Fibers or cloth are pulled through a resin bath Heated in a die with a shaped profile Cured to shape Cut to length

11. Metal Matrix Composites Completely different field. The book has them in the same chapter, but they are very different. Combination of metal matrix, with ceramic reinforcement. Examples: Titanium with SiC fiber reinforcement Titanium with SiC fiber reinforcement Mg with SiC discontinuous reinforcement Mg with SiC discontinuous reinforcement