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Transcript of ME 7502 Lecture 1 - Dr. Brian Sullivanvucoe.drbriansullivan.com/wp-content/.../Lecture-1... · ME...
ME 7502 Introduction - Dr. Brian J. Sullivan 1
• Definitions • Particulate Composites • Laminated/Lamellar Composites • Fiber Composites • Fiber Composite Manufacturing Processes • Applications of Composite Material and
Structures • Composite Material/Structural Design Process • Matrix Algebra • MathCAD
ME 7502 Lecture 1 – Introduction to Composite Materials and Composite Structures
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DEFINITIONS COMPOSITE MATERIAL: A MATERIAL SYSTEM COMPOSED OF TWO OR MORE DIFFERENT, INSOLUBLE MATERIAL PHASES
MATRIX PHASE: A MATERIAL PHASE CONTINUOUSLY CONNECTED TO ITSELF
INCLUSION OR REINFORCEMENT PHASE: A MATERIAL PHASE COMPLETELY SURROUNDED BY MATRIX WHICH USUALLY APPEARS AS MANY DISCRETE UNCONNECTED GEOMETRICAL PARTS
PHASE VOLUME FRACTION vp = vol. of phase/total vol.
PHASE WEIGHT FRACTION wp = wt. of phase/total wt.
wm = matrix wt. fract. vm = matrix vol. fract.
w/o = weight percent v/o = volume percent
wp = particle wt. fract. vp = particle vol. fract.
wf = fiber wt. fract. vf = fiber vol. fract.
wi= inclusion wt. fract. vi = inclusion vol. fract.
WEIGHT VOLUME
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UNIDIRECTIONAL FIBER
PARTICULATE
LAMINAR/LAMINATED FLAKE FILLED
2-D WOVEN 3-D WOVEN BRAIDED
SHORT FIBER
TYPES OF COMPOSITES
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PARTICULATE COMPOSITES INCLUSIONS HAVE 3 DIMENSIONS ON SAME ORDER OF MAGNITUDE
• DISPERSION-HARDENED METALS • METAL (Al, Steel)/POLYMER - INCREASE ELECTRIC/THERMAL CONDUCTIVITIES • METAL/CARBON - RESISTORS • CERMETS (CERAMIC INCLUSION/METAL MATRIX) - UP TO 30% VM
Al2O3/Cr ---------- LOW MOLTEN-METAL-WETTING, LOW FRICTION, MgO/Cr ---------- RESIST THERMAL SHOCK, EROSION, ABRASION, FLAME, HIGH THERMAL CONDUCTIVITY
W Carbide/Co, Cr Carbide/Co, Ti Carbide/Co ---------- GOOD RESISTANCE TO ABRASION, IMPACT, USED IN MOLTEN METAL FLOW GUIDES, WIRE DIES, PRECISION ROLLS, GAGES, VALVE PARTS, CUTTING TOOLS • FILLER/POLYMER
Ca Carbonate, Clay LOW COST, HIGHER STIFFNESS Glass µ spheres MOLDED ITEMS, AUTO PARTS
Carbon/Rubber
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LAMINATED/LAMELLAR COMPOSITES REINFORCING PHASE HAS ONE DIMENSION MUCH SMALLER THAN THE OTHER TWO
LAMELLAR FLAKE / MATRIX GLASS POLYMER (EPOXY, PHENOLIC, POLYESTER) METAL METAL (Al, Iron) AlB2 GRAPHITE HIGHER E, K, Strength, etc., THAN MATRIX, GREATER PACKING DENSITY THAN PARTIC., LOWER COST THAN FIBERS
AlB2 flake
LAMINATED -METAL CLAD/COATED METALS Al/U Ti/Steel Cu/W Al/Be Ni, Cu, Al, Au, Ag, Sn, Pb/Mo (Electrical, Chemical, Thermal Applications) -CERAMIC/METALS, CERAMIC/CERAMIC (CORROSION, HEAT-RESISTANT) -PAPER/POLYMER -LAMINATED UNIDIREC. & WOVEN Gr/Ep
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FIBER COMPOSITES
FIBER GLASS GRAPHITE/CARBON BORON SiC
OXIDE
LAMINATE UNIDIRECTIONAL OR WOVEN, STACKED MULTIDIRECTIONALLY
SHORT FIBER “CHOPPED” FIBER
1/4” - 2”
CONTINUOUS FIBER FILAMENT - SINGLE STRAND ROVING - 10-200 “ENDS” TOW - 1,000-10,000 “ENDS”, NOT TWISTED YARN - 1,000-10,000 “ENDS”, TWISTED
+MATRIX
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SHORT FIBER COMPOSITES SHORT (25 mm) FIBERS + FILLER + RESIN
(a) SMC-R30 (b) SMC-C40 R30 (c) XMC
SMC-R SHEET MOULDING SMC-CR XMC COMPOUND FIBERS 25-30%W SMC-R + SMC-CR, BUT RESIN 30%W CONTINUOUS FIBERS CONTINUOUS FILLER 40-45%W FIBERS @ ±5-7°
SHEET FORM
HMC - STRUCTURAL GRADE SMC (60-65%W FIBERS) BMC - BULK MOLDING COMPOUND - SMC IN BULK FORM
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HIGH-PERFORMANCE FIBER COMPOSITES MULTIDIRECTIONAL, CONTINUOUS FIBER COMPOSITE
FIBER PHASE GLASS
GRAPHITE (CARBON)
BORON
ARAMID (KEVLAR)
CERAMICS
- SiC
- OXIDE
MATRIX PHASE POLYMERS
CERAMICS
METALS
TOW (1K-10K ENDS)
TAPE
FILAMENT WINDING
ROVING (~100 ENDS)
YARN (TW 1K-10K ENDS)
WOVEN FABRIC
BRAIDED PREFORM
3-D WOVEN PREFORM
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WOVEN GLASS ROVING
BORON TAPE
BRAIDED PREFORM KEVLAR 49 TOW
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TAPE OR THERMOSET
FABRIC RESIN + “PREPREG”
PLY STACKING CERAMIC MATRIX TAPE OR FABRIC +
FIBER COMPOSITE LAMINATE
FILAMENT WINDING TOW + RESIN
-HIGH STRENGTH -LOW WEIGHT
-HIGH STIFFNESS -TAILORABILITY OF THERMO-MECHANICAL PROPERTIES
-GOOD FATIGUE CHARACTERISTICS
-CMCs : EXCELLENT HIGH TEMPERATURE APPLICATIONS
(CMC)
(PMC)
(PMC)
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FIBER COMPOSITE LAMINATE - INDIVIDUAL PLY MAY BE UNIDIRECTIONAL OR WOVEN
STACKING SEQUENCE/PLY LAY-UP SYMMETRY [0/+45/-45/-45/+45/0] = [0/+45/-45]S
REPEATED SEQUENCE [0/90/0/90] = [0/90]2 [0/0/+45/-45] = [02/+45/-45] COMMON LAY-UPS : [0i/±45j/90k]s ; [0i/±θj] [0/+45/-45/-45/+45/0] [0/±45]S OR [02/±45]S - BENDING, TORSION [0 /±45/90]S - [0/±60]S - QUASI-ISOTROPIC
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FIBER COMPOSITE MANUFACTURE
THERMOSET MATRIX, CONTINUOUS FILAMENTS
Manual Lay-up... •-APPLY GEL COAT, FIBERS, RESIN •-POSITION PREPREG •-APPLY FIBERS / WOVEN FABRIC, INJECT RESIN
...+cure •-FREE CURE (R.T. THERMOSETS) •-VACUUM BAG OR PRESSURE BAG, THEN AUTOCLAVE (250° - 350°F, 50 - 100 psi) •-COLD PRESS MOLDING (RT) OR •-MATCHED METAL DIE COMPRESSION MOLDING
(250° - 350°F, 200 - 1500 psi)
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Filament Winding Sheet Continuous Lamination Pultrusion
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THERMOSET MATRIX, SHORT FIBERS Manual Lay-up of Prepreg, Cure Sheet Continuous Laminating Spray-Up
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THERMOPLASTIC MATRIX Pultrusion (Continuous Filaments) Injection Molding (Short Fibers) Extrusion Hot Forming (Preformed Sheets)
METAL MATRIX Diffusion Welding -Press/Sinter Matrix Powder, Bare/Coated Fibers -Press Coated Fibers -Press Fibers between Foil (+Powder) Liquid Wetting -Liquid Metal Infiltration of Fibers -Heat Powder & Fibers above Matrix Solidus Deposition -Matrix electrodeposition, Vacuum deposition, or Plasma Spray onto Fibers, Press
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RESIN MATRIX PROCESSES Hand Layup Vacuum Bag Layup
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Pressure Bag Molding Auto-clave Molding
ME 7502 Introduction - Dr. Brian J. Sullivan
RESIN MATRIX PROCESSES (cont’d)
• Out-of-Autoclave Composite Manufacturing offers – Reduced recurring costs – Reduced cycle times for primary structures – Potential improvements in quality by reducing
pressure and resin flow – Utilizes resins specifically engineered for lower
pressure, lower temperature cures – Can enable manufacture of some very large
primary composite structures – Co-cures of separately fabricated parts facilitated
by successful out-of-outclave manufacturing
ME 7502 Introduction - Dr. Brian J. Sullivan 18
RESIN MATRIX PROCESSES (cont’d)
• Out-of-Autoclave Composite Manufacturing methods include: – Vacuum Bag Only – Resin Transfer Molding (RTM) – Vacuum Assisted Resin Transfer Molding
(VARTM) – Balanced Pressure Fluid Molding – Microwave Curing – Prepreg compression molding – E-Beam Curing
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RESIN MATRIX PROCESSES (cont’d)
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Ceramic Matrix Composite Processes 3 Main Types: a. Chemical Vapor Infiltration (CVI)
1) Requires extensive facilitation (furnaces to deposit chemical composition of matrix phase through vapor infiltration)
2) Results in the fabrication of high quality CMC parts 3) Very economical process for large lots of parts but not
inexpensive for small lots b. Polymer Infiltration and Pyrolysis (PIP)
1) Facilitization requirements are not as extensive – matrix infiltration is very similar to OMC parts
2) Parts are usually of lower quality than CVI parts 3) Economical for small lots of CMC parts – quite costly for large
lots of parts c. Melt Infiltration (MI)
1) Requires special high temperature furnaces to melt silicon metal being infused into the prepreged composite
2) Parts can be very high quality 3) Process has not yet been used for large lots of parts; currently
cost lies between CVI and PIP ME 7502 Introduction - Dr. Brian J. Sullivan
C/SiC Overview
• 3000F + Temperature Capability • High Specific Strength • Non-Oxidizing Matrix • Matrix CTE Compatible with EBC • High Durability with EBC Coating
Environmental Barrier Coating
C Fiber Fiber/Matrix Interface Coating SiC CVI Matrix
C/SiC
Attributes
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Photomicrograph from A. Calomino NASA GRC
C/SiC Microstructure
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C/SiC Manufacturing Process
CVI Carbon Fiber
Interface
CVI SiC Protective Coating
CVI SiC Densifi-cation
Customer Design
Customer CTQ’s
Composite Design
Tooling and Process Design
Textile Processes
2D/3D
Heat Treat and
Prepreg
Machining
Preform Lay-up
& Tooling
Autoclave
C Fiber Pan or Pitch Inspection
C/SiC
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Preforming Capability Fabric Cutters
Heated Presses
Autoclaves
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CVI Reactors
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CMC Machining Capability
Weldon CNC Cylindrical Grinder
HAAS VFZ Mill, 4-Axis CNC
HAAS VR II Mill, 5-Axis CNC
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CMC Analysis, Testing & Inspection Capability IR NDE
Mechanical Testing
SEM
Optical Microscopy
CMM
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C/SiC Manufacturing Process
CVI Carbon Fiber
Interface
CVI SiC Protective Coating
CVI SiC Densifi-cation
Customer Design
Customer CTQ’s
Composite Design
Tooling and Process Design
Textile Processes
2D/3D
Heat Treat and
Prepreg
Machining
Preform Lay-up
& Tooling
Autoclave
C Fiber Pan or Pitch Inspection
C/SiC
Tooling may be required
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Preform Tooling Required: All Parts Types: Similar to Polymer Matrix Composites
• Materials Metals, Graphite, Plastic
• Design Concerns CTE, Debulk Pressure, Assy/Disassy
Release Applied
Preform Layup
Vacuum Debulk
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CVI Tooling Required: During CVI PyC and 1st CVI SiC Types: Perforated Graphite
• Materials Purified Graphite
• Design Concerns CTE, Preform Pressure,
Assy/Disassy
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Fabric Descriptions 2D Fabric • Balanced Plain Weave (MS5005900) • T300® 1K Tow (MS5005800) • Heat Treat: Maximum Use Temperature (MS5006900) • Prepreg: Fugitive Binder as a Manufacturing Aid (MS5007000)
50 yard rolls of fabric ready for Heat Treatment
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Fabric Descriptions Draping 2D Fabric • Draping analyses performed on complex shapes • Shear maps used for ply design and layup • Plain weaves shear < satin weaves
Combustor Liner Draping Analysis
Combustor Liner Preform
T.E.A.M. Inc. textile engineering and manufacturing
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Fabric Descriptions 3D Weave • Orthogonal, Angle and Layer Interlock Constructions • T300® 1K and 3K • Pros:
• Cons:
Angle Interlock
Layer Interlock Angle Interlock Fill View
Orthogonal
Size limitations due to limitations in weaving equipment Inplane property knockdown with minimal across-ply
property improvement
Can bias reinforcement No delaminations
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Braids • 2D Braids • 3D Braids: Cartesian and Lockstep Processes • T300® 3K max (CVI Requirement) • Pros: Can conform to complex geometries • Cons: Size limitations due to limited number of braiding carriers
Fabric Descriptions
2D Flat Braid
2D Triaxial Braided Thruster and close-up of throat prior to machining
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• Most common is carbon fiber reinforced carbon matrix (C-C) – aircraft brakes, rocket nozzles
• Carbon fiber reinforced silicon carbide matrix (C/SiC) – Space Shuttle TPS repair parts, rocket motor thrusters
• Silicon carbide reinforced silicon carbide matrix (SiC/SiC) – jet engine (flaps and seals, combustor liners) and turbine engine components (stator vanes)
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Types of Ceramic Matrix Composites and their Applications
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C/SiC Cover Plate Flexes to Conform to WLE
C/SiC Cover Plate
Concept Description • Flexible 7-in MCM-700 coated C/SiC
cover plates • Cover plates flex and conform to WLE
within 0 to 5 mils • TZM attach hardware coated with
R512E and MCM-700 • 20 to 30 unique plug geometries
required to provide coverage of all WLE panels to within 1” of T-seals
• Uncured NOAX edge sealant is being developed for edge gaps exceeding 20 mils
• Capable of repairing RCC damage with a maximum dimension of 6”
Status • 13 Plug Repair Panels on ISS • 6 additional Plug Repair Panels by
7/06
TZM Attach Hardware
Space Shuttle “Return to Flight” Plug Repair
Inserting Plug Assembly
Back View of Installed Plug Assembly
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Aft end of the engine for the F-18 Super Hornet showing CMC flaps and seals after 500 sorties in Iraq War
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CONSTITUENT & COMPOSITE PROPERTIES
MATRIX PROPERTIES (R.T.)
UTS (kpsi)UCS (kpsi)
THERMOSETS3.-10.20.-65.
620y
8.717Y
814.5Y
2.5-9.7.6Y
-5.580.7476.3
STEEL (1040) 0.28 30 85 (YP) 6ALUMINUM (7075-T6) 0.095 10 73 (YP) 13.3GLASS (1/2 in. ROD) 0.09 10 10 9GRAPHITE (BULK) 0.067 1.3 3 2.-4.*ACRYLONITRILE BUTADIENE-STYRENE
ρ (pci) E (Msi) α (µ°F-1)MATERIAL
440.330.038
0.058
0.4 30
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0.049 1.3 14
0.044 .3-.6
THERMOPLASTICS
CERAMICS
0.043
EPOXY to 250°F
POLYIMIDE to 600°F
ACRYLIC
POLYESTER
ABS*
3.96
8.370.0828SILICON CARBIDE (SiC)
OTHER
4.21
ALUMINUM OXIDE (Al2O3) ALUMINA
0.112 8.19
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FIBER PROPERTIES (R.T.)
MATERIAL ρ (pci) E (Msi) UTS (kpsi) α (µ°F-1)E-GLASS 0.092 10.5 500 2.8S-GLASS 0.09 12.4 650 1.6ARAMID-KEVLAR 29 0.052 9 550 -KEVLAR 49 0.053 19 550 -1.1GRAPHITE (TYPICAL) 0.066 33-75 425-250 -0.6BORON 0.1 60* 530* 2.7ALUMINUM OXIDE (Al2O3) 0.134 55 250SiC 0.112 60 550
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COMPOSITE PROPERTIES FILLED EPOXY RESINS (PARTICULATE)
SMC (SHORT [0.5-2 in] FIBER/POLYESTER MATRIX)
FILLER wi, w/o E (Mpsi) SUT (ksi) SUC (ksi)
29 0.53 2.37 10.1844 0.73 3.38 10.3755 0.81 3.49 10.5129 0.51 2.47 10.0944 0.62 2.88 9.6829 0.47 2.76 9.4244 0.62 2.5 9.5
CaCO3
CLAY
SOLID GLASS SPHERES
2.36 10.46-NONE 0.37
FIBER vf v/o E1 (Mpsi) S1ut (ksi) (E2 ~ 0.8E1)GLASS 33 1.7 15 (S2ut ~ 0.8S1ut)
CARBON 35 3.9 15GLASS,
CARBON24, 26
3.5 17
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FIBER COMPOSITE PROPERTIES vf = 0.6
[0] UNI. E1 (Mpsi) E2 (Mpsi) S1t (kpsi) S1
c (kpsi) S2τ
S2-GL/EP 7 2.0 220 130 8
HM GR/EP 32 1.4 200 180 7KEV 49/EP 12 1.0 200 40 4B/EP 36 3.6 250 360 13
[0/±45/90] Q/I Ex (Mpsi) Sxt (kpsi) ρw (pci)
S2-GL/EP 2.2 88 0.070HM GR/EP 9.0 80 0.055KEV 49/EP 4.0 60 0.047B/EP 10.0 100 0.073
[0/90] Ex/ρw (M*in) Sxt / ρw (k*in)
S2-GL/EP 64 1760H GR/EP 304 2040KEV 49/EP 138 1900B/EP 271 19201040 STEEL 107 3047075-T6 AL 105 768
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COMPARISONS
[0/90] FIBER/EPOXY, Vf = 0.6
S2-GL/EP
KEV 49/EP
HM GR/EP
B/EP
7075-T6 AL
1040 STEEL
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
2.2
0 50 100 150 200 250 300 350
E x / ρ (M*in)
S UT /
ρ (M
*in)
ME 7502 Introduction - Dr. Brian J. Sullivan
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COMPARISONS
Strength Vs. Temperature
0
20
40
60
80
100
120
140
160
180
0 500 1000 1500 2000 2500 3000 3500 4000
Temperature (°F)
Stre
ngth
(ksi
)
Steel 3D-Pitch Carbon-Carbon
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SUMMARY GL/EP: GOOD STRENGTH/WEIGHT, CHEAP, NON-CONDUCTING (ELECTRICITY) LOW STIFFNESS/WEIGHT GR/EP: GOOD STRENGTH/WEIGHT, STIFFNESS/WEIGHT, ZERO AXIAL THERMAL EXPANSION, EXPENSIVE, FLAMMABLE, CONDUCTS ELECTRICITY KEV49/EP: GOOD TENSILE STRENGTH/WEIGHT, IMPACT RESISTANT, MODERATE COST ZERO AXIAL THERMAL EXPANSION, POOR COMPRESSIVE STRENGTH, MODERATE STIFFNESS/WEIGHT B/EP: GOOD STRENGTH/WEIGHT, STIFFNESS/WEIGHT, OUTRAGEOUSLY EXPENSIVE HYBRIDS: COMBINE REINFORCEMENT LAYERS TO ADVANTAGE CMC: EXCELLENT HIGH TEMPERATURE STRENGTH, HIGH CORROSION RESISTANCE
ME 7502 Introduction - Dr. Brian J. Sullivan