1. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 1 Lecture 2 ADVANCED COMPOSITES Fabrication Technology  Autoclave Molding  Filament Winding  Pultrusion  Resin Transfer Molding (RTM)

2. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 2 Polymer Matrix vs. Advanced Composites Polymer Matrix: High strength, stiffness fibers in weak matrix Advanced Composites: Carbon (C)/Graphite (Gr) Kevlar (K), Boron (B), Glass (Gl) Reinforced Plastics:  Mostly E-glass fibers.  Discontinuous./ continuous reinforcement  Relatively low moduli Advanced Composites  Carbon (C)/Graphite (Gr) Kevlar (K), Boron (B), Glass (Gl)  Continuous reinforcement  Relatively high moduli

3. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 3 Advantages MaterialDensity (g/cc) Tensile Modulus (Msi) Tensile Strength (Ksi) Eng. Plastic Reinf’d Eng Plastic Wood (0  ) Steel (low c) Al (6061-T6) HTS (Gr/Ep(0  ) 1.0-1.4 1.2- 1.6 0.5 8.0 2.8 1.6 0.3-0.6 0.6-2.0 1.5 30 10 21 6-20 8-30 15 45 180 Design flexibility not present in metals; in metal only material selection BUT in composites designer/creator.

4. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 4 Design Flexibility

5. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 5 Applications Aerospace Automotive Consumer Industrial - Aircraft components, wings, fuselage Empennage, substructure, interiors - Helicopter components - Satellite - Missiles - Body panels, interiors, engine brackets - Drive shaft - Springs - Boats, appliances housings, toys - Sporting goods - Pressure vessels - Pipe - Drilling rigs

6. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 6 Unidirectional vs. Cross-plied

7. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 7 Cont.

8. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 8 The Payoffs Lower weight Higher speed Increased load capacity or range Better fuel economy Improved maneuverability and response Longer lifetime (corrosion, fatigue, stress rupture) Dimensional stability Lower initial and life cycle cost

9. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 9 Assignments (Due 10-6, Mid-term Week) Make a search in the net for (Advanced Composites). - Find three papers. - Make a summary for each. - Submit both the paper and the summery. (Due 24- 7, Finals Week) Project: Make a group of four Pick up a project; make a report and presentation.

10. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 10 The project should include:  Background  Objectives  Functional design, Design specifications, Design criteria and Deliverables  Preliminary designs  Material selection  Assembly  Fabrication  Durability/environmental exposure/ repair  Costing and certification  D&R  Conclusion

11. Mechanical Engineering Department Advanced Composites Dr. Talal Mandourah 11 Quiz1