A Comprehensive Guide to Composites

Processes & Procedures from the Professionals

Kevin Fochtman

• Publisher: Aviation Supplies & Academics, Inc.
• Year: 2014
• eBook ISBN: 9781619542051
• Topic: Technology & Engineering
• Subtopic: Materials Science
• Index: Technology & Engineering

This is the Ebook (ePub) edition of this title.Graphite, carbon fiber, Kevlar, prepregs -- these are advanced composites in wide use by today's manufacturers. The processes and skills needed to produce composite parts and components are unique; training in this high-skills sector is vital and opens up many opportunities to employees and apprentices in the industry.This book provides an insider's viewpoint on the tips and techniques used by the pros to fabricate advanced composite parts. The culmination of more than 30 years of industry experience, it imparts valuable insight on safety, shop and equipment needs, engineering, materials, lay-up, fabrication and quality control. The author captures lessons, games, safety, tests and projects in place, explaining them in the most pertinent context possible. Students and instructors will benefit from his coverage of lean manufacturing, STEM, and advanced composites, all in one book.Composite manufacturing skills are marketable and in high demand, especially in the aerospace, automotive, sports, medical, marine, and construction industries. After reading this book, not only will students understand the basic skills required by today's composite industry, they will also have foundational knowledge to pursue higher education goals in material science, composite engineering, composite research and development.

Introduction

Objectives

A. Defining composites

B. Typical applications

C. Deciding on a program level

According to the Advanced Composite Materials Association (ACMA), the U.S. dominates the advanced composites industry in manufacturing, product research and distribution. There are more than 500,000 people employed in upwards of 7,000 advanced composite companies, producing everything from airplane bodies to sports equipment and automobile parts. The $70-billion-dollar industry’s projected ten-year growth rate is nearly 8%, which presents an array of opportunities for a highly skilled worker.

What Are Advanced Composites?

Composites are also known by the industry term fiber-reinforced polymer or FRP. Advanced composites are characterized by the use of expensive, high-performance resin systems and high-strength, high-stiffness fiber reinforcement.

A polymer matrix resin, sometimes referred to as plastic, is either thermoplastic or thermoset resin. A thermoplastic is a polymer that becomes pliable or moldable above a specific temperature, and returns to a solid state upon cooling. A thermoset is polymer material that irreversibly cures. The cure may be done through heat (generally above 350°F), through a chemical reaction (two-part epoxy, for example), or irradiation such as electron beam processing. Common thermoset resins include polyester, isopolyester, vinyl ester, epoxy, and phenolic. To reinforce the resins we use fibers such as glass, carbon, aramid, graphite or other reinforcing material.

The combination of these materials results in a discernible reinforcing function in one or more directions along the aspect ratio (length to thickness). FRP composite may also contain fillers, additives, and core materials.

There are a number of exotic resins and fibers used in advanced composites, however, epoxy resin and reinforcement fiber of aramid, carbon, or graphite dominates this segment of the market. These materials have been adopted by an enormous range of industries touching our everyday lives. Advanced composites provide high strength-to-weight ratios which enables engineers to design high performance parts. ACMA estimates that more than 50,000 new products could utilize advanced composite materials.

Composite Applications

Aerospace

Composites used in commercial airliners have made tremendous strides over the past 40 years. The first 747 that rolled out of Boeing’s Everett, Washington production facility contained just 1% composite materials. Today more than 50% of the 787 Dreamliner is built with composites, including the world’s first all-composite fuselage. The Airbus A350 XWB is more than 50% composites, as it prepares to enter service in 2014. Typical composite uses include: air frames, wing spars, tail-fins, spoilers, fuel tanks, bulkheads, flooring, helicopter rotor blades, propellers, pressurized gas containers, radomes, engine nacelles, air distribution ducts, seat components, access panels, and more. Carbon fiber composites are used in elevated temperature applications such as disc brakes and static components in jet engines. Rocket motor casings and rocket launchers are also frequently made of reinforced plastics.

Automotive Engineering

Mandates to increase fuel economy over the next twenty years are driving weight reduction throughout the assembly. Advanced composites (carbon, aramid, graphite) are not as frequently used as glass-reinforced plastics (GRP) because of the costs. Typical uses include: car and truck body moldings, panels and doors, fascias, bumper moldings, and trim packages. Based on the high energy-absorbing capacity of composites, many manufacturers use them in controlled crush components.

Bioengineering

Composites are widely used as prostheses for amputees. In running, carbon fiber prosthetics ‘flex’ which provides for kinetic energy storage, thus greatly increasing a runner’s performance level. As arms and hands, composites are light, strong and malleable. The bebionic3, features microprocessor controlled motors in each finger. This allows for a multitude of grips and hand positions previously out of reach with wood and rubber models.

Chemical Engineering

Typical uses in this sector include: pressure vessels, containers, valves and pipe-work.

Construct...

Table of contents

• Preface
• Chapter 1: Introduction
• Chapter 2: Safety & Health
• Chapter 3: Equipment
• Chapter 4: Facility Design and Preparation
• Chapter 5: The Lay-Up Mandrel (aka “The Tool”)
• Chapter 6: Engineering and Planning
• Chapter 7: Materials Review
• Chapter 8: Fabrication
• Chapter 9: Quality Assurance
• Appendix A: The 8-S Program for Life and Work
• Appendix B: Material Shelf Life Defined
• Appendix C: Material Log Sheet
• Glossary of Terms
• Bibliography
• About the Author
• Index