Overview Of Advanced Composite .

Overview of Advanced CompositeMaterials and StructuresAbout these slides: The center on Advanced Materials In TransportAircraft Structures (AMTAS):- was established in 2003- is part of the FAA Center of Excellence programgUW ((lead),), WSU,, EdCC,, OSU,,- involves 6 colleges/universities:UoU, and FIU- involves several aerospace companies (primarily Boeing)- maintains a website with additional details:http://depts.washington.edu/amtas/

Overview of Advanced CompositeM t i l andMaterialsd StStructurestAbout these slides: A composite short course intended for practicing engineerswas developeddldbby AMTAS participantsti it These slides were extracted from the AMTAS short course

AcknowledgementsJohn GokcenDick BossiEi CEricCreggerDave DicksonChris EastlandDoug McCarvilleMoe SoleimanPatrick SticklerBruno BoursierDayton GriffithDave KehrlPeter JanickiJohn WellerDodd GrandeEric CasterlineFrank KoBud DasPaolo FeraboliBrian FlinnKuen LinMark Tuttle

Overview:Advanced Composite MaterialsWhat is a ‘Composite Material’?“A composite material is one in which two (or more) materials arebonded togethergto form a third material.” is a material consisting of:93.5% Al, 4.4% Cu, 0.6% Mn,1.5% Mga composite?(this material is known as the 2024 aluminum alloy)- No,N 2024 Al isi nott consideredid d tto bbe a compositeit- Definition is missing a reference to physical scale

Overview:Advanced Composite MaterialsWhat is a ‘Composite Material’?“A composite material is a material system consisting of two (ormore)) materials that are distinct at a pphysicalyscale ggreater thanabout 1 x 10-6 m (1 m), and which are bonded together at theatomic and/or molecular levels.”To put this physical scale in context: the diameter of the human hair ranges from 30-60 m objects with a dimension of 1 m can be easily seen withan optical microscope

Overview:Advanced Composite Materials Composites typically consist of:– Relatively strong and stiff reinforcing material, that is– Embedded within a relatively weaker and more compliantmatrix material Compositesphave been used for centuries ((clayy bricksreinforced with straw; papyrus reeds embedded in anatural pitch matrix; etc) Composites occur naturally: Wood: cellulose fibers in a lignin matrix Bone: collagen fibers in a (mostly) calcium phosphate matrix

Overview:Advanced Composite Materials ‘Advanced’ (or ‘modern’) composites areengineered materials developed within pastpast 80 yrs First commercially successful advanced compositeis commonly known as ‘fiberglass’: glassreinforcingg fibers embedded within a ppolymerymatrix (usually polyester, vinyl ester, or epoxy) Advanced composites often classified according to– Type of matrix material, or– Physical form of reinforcing material

Overview:Advanced Composite Materials Classification by type of matrix material:– Polymer Matrix Composites (PMCs) e.g., polyester, epoxy, bismaleimide, phenolic matrices– Metal Matrix Composites (MMCs) e.g., aluminum, titanium or magnesium matrices– Ceramic Matrix Composites (CMCs) e.g., silicon carbide (SiC), silicon nitride (Si3N4), aluminum oxide(Al2O3) matrices Approximate maximum service temperatures: PMCs: upp to about 350ºC ((630ºF),), dependingpg on ppolymery MMCs: up to about 500ºC (900ºF), depending on metal CMC: up to about 1200ºC (2100ºF), depending on ceramic

Overview:Advanced Composite Materials Classification by physical form of reinforcing material:– Particulate: roughly spherical reinforcing particles withdiameters 1-100 μm– Whisker:Chopped diameters 5-30 mglassfiber lengths 10 mm– Short (or "chopped") fiber: diameters 5-30 m lengths 10 200 mmContinuous– Continuous fiber:glass fiber diameters 5-30 m lengths, in effect, infinite

Overview:Advanced Composite MaterialsThe remainder of this review (and ME450 as awhole!) is devoted to polymeric matrixcomposites10

Overview:Advanced Composite MaterialsAlthough originally developed for aerospace, the useof composites has expanded into many ositeMaterials andTechnologiesAutos &TrucksRecreationMedicalSpecialty11

Overview:Advanced Composite Materials12

Overview:Aerospace applications Fiberglass introduced in 1930’s (originally used in tooling)and 1940’s (aircraft secondary structures) Boron fibers introduced in the early 1960s GlassGl(i(improved),d) carbon,bandd aramidid (K(Kevlar)l ) fibfibersintroduced in the late 1960s and led to the increased use ofadvanced composites (particularly in military aircraft). Through the 1970s and early 1980s composite resins werebrittle (e.g., “epoxy”), limiting (commercial) applications tosecondary structural applications.applications In the late 1980s resin toughening technologies werep ((e.g.,g “rubber-toughenedgepoxy”)p y ) pavingpg thedevelopedway for the more extensive use of composites in primary13structural applications.

Overview:Aerospace applications Boeing 777: Entered commercial service in 1995;– Composites account for about 10% of total structural weight– The graphite-epoxy empennage (i.e., the tail section) was the firstcompositepprimarypy structure used in a Boeingg commercial aircraft Boeing 787: Entered commercial service Sept 2010– CCompositesiaccount ffor 50%0% off totall structurall weighti h– Features a graphite-epoxy fuselage, empennage, and wings– Uses 20% less fuel than other aircraft of similar size, primarily dueto light-weight composite structure Boeingg 777X: Enter commercial service in 2020 ((?))– Composite wings – Composite weight percent ?14

Overview:Commercial Transport AircraftUse of composites in Boeing 727 (1963-84)15

Overview:Commercial Transport AircraftUse of composites in Boeing 737 (1968-present; several models)16

Overview:Commercial Transport AircraftUse of composites in Boeing 777 (1995-present; several models)17

Overview:Commercial Transport AircraftUse of composites in Boeing 787 (Sept 2011; 3 models planned)OtherSteel 5%10%Carbon laminateCarbon sandwichOther mposites50%18

Overview:Commercial Transport Aircraft

Overview:Commercial Transport AircraftUse of composites in Airbus 380 (2007-present; two models)

Overview:Commercial Transport AircraftComposites in the Airbus 350 (first commercial flight: 15 Jan 2015)

Overview:Military Aircraft extensive use of composites in primary structures since 1970sF/A-18 A/B(Hornet) firstflew in 1976

Overview:Military AircraftAV-8B (Harrier)first flew in 1978

Overview:Military AircraftRotorcraft (typically helicopters)hhaveusedd fibfiberglasslblbladesd forfimproved fatigue resistance fordecades.Other structural componentsnow made from carboncarbonepoxy to save weight andincrease performance, as inthe Comanche (above) andthe Osprey (right)

Overview:Space VehiclesCompositesCit hhave bbeen usedd extensivelyti l iin bboththexpendable and reuseable launch vehicles

Overview:Space StructuresComposites are used in the International Space Station

Overview:Space StructuresAll-composite crew module forO iOrionexplorationltivehiclehi l bbuiltiltby NASA (engineering andtoolingg supportppfrom JanickiIndustries)

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Overview:Marine Applications41′ Hunter Sailboat(www signature-yachts com)(www.signature-yachts.com)147′ Gran Finale Yacht(www.deltamarine.com)18′ 5″ Reinell Runabout((www.reinell.com)i ll)

Overview:Marine ApplicationsHull,, mast,, & boom of the BMW-Oracle RacinggYacht produced using carbon-epoxy composites

Overview:Marine ApplicationsThe 58-meter carbon fiber fixed wing-sail on the BMWOracle AC33 trimaran is larger than a B-747 wing

Overview:Advanced Composite Materials32

Overview:Automotive ApplicationsHigh-end,Hih d hihigh-performancehfcars: ’53 CCorvettett ffeaturedt dcomposite body produced using fiberglass mathttp://auto howstuffworks com/corvette-pictures .htm

Overview:Automotive ApplicationsGM Corvette Z06 (2013 model shown)- Body: fiberglass woven fabric- Hood:H d unidirectionalidi til carbonb fibfiber- Front wheelhouse: CMC* w/ glassmicrospheres for weight reduction (1.1pGravity)y)Specific- Floor boards: CMC* skins over ½”balsa wood core- 2014: Body panels produced using newpressure press equipment developed“pressure-press”by Globe Machine Manufacturing(Tacoma)FlFloorBoardsBdFront Wheelhouse

Overview:Automotive ApplicationsThe Lamborghini Aventador LP700-4 features manycomposite components, including a carbon fiber chassisproduced using resin transfer molding ///?

Overview:Automotive ApplicationsAdvanced composites routinely used in high-performancerace cars (Example: Honda F1 uses autoclave-curedautoclave cured carboncomposite chassis, suspension, wings, gear box, andengine cover)

Overview:Automotive ApplicationsComposites in the UW FSAE Car steadily increased since 1990cCarTeam 1 (1990)eCarTeam 26 (2015)

Overview:Automotive Applications Extensive use of structural carbon composites in highvolume production vehicles (Chevy MalibuMalibu, Ford TaurusTaurus,Toyota Camry, etc) has been inhibited due to both highmaterial costs and low production rates (resulting in highmanufacturing costs) The Automotive Composites Alliance (ACA) tracks theuse of composites in (relatively) high-volume ex.cfm( .info may be dated )

Overview:Automotive Applications

Overview:Automotive Applications IIncreasedd use off structuralt t l compositesit ini productiond tivehicles beginning to occur due to:– Need for improved fuel efficiencies & lower emissions– Changes in design philosophies (reduction in part count)– Improved manufacturing processes (i.e., increasedproductiond ti rates)t )– “Some” reduction in material costs

Overview:Automotive ApplicationsSGL/Automotive Fiber Composites facility opened near Moses Lakein 2011(a joint venture with BMW)BMW) producesproduces carbon fibers andfiber fabrics:http://www.sglacf.com/en.html

Overview:Applications in Heavy Trucks

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Overview:Energy Applications: Wind Windmills used for hundred of years ManyMan “out“o t of the bobox”” concepts proposed togenerate electricity (windmills wind turbines)Photo a.org/wiki/Wind turbine#VAWT subtypesiki di/ iki/Wi d t bi com/energy/2006/04/turby vertical .html

Overview:Energy Applications: Wind Most modern wind turbines based on horizontalaxis and three composite blades Commercially available wind turbines range fromthose intended for home use.200 W Air Breeze www.windenergy.com10 kW BWC EXCELwww.bergey.com

Overview:Energy Applications: Wind to those used in large wind farms that providepower to entire communitiesStateline Wind Project,near Columbia GorgeGorge,WA-OR border(www.rnp.org/Projects/stateline html)stateline.html)Danish Horn Revoffshore m)i t/ ff hht )

Overview:Energy Applications: WindTrend is towards very large turbines

Overview:Energy Applications: Wind Composite blades traditionally produced usinginexpensive fiberglass and wet-layup techniques As windmill sizes have increased new designdrivers have emerged:– Gravity/wind induced bending loads– Blade stiffness– Transportation}Increasinguse ofadvancedcarbon fibers

Overview:Energy Applications: WindTransportation issues Fiberglass blades produced by LM Glasfiber (Germany); photocourtesy of Dayton Griffin, Global Energy Concepts (Seattle, WA)

Overview:Energy Applications: Tidal In early stage of development site evaluations underwayi EinEurope, CCanada,d andd US Several operating test sites in Europe (www.emec.org.uk) University of Washington is member of the NorthwestN iNationallMMarinei RRenewablebl EEnergy CCenter (NNMERC)Seven potential sites in Puget Sound being evaluated:http://depts washington edu/nnmrec/http://depts.washington.edu/nnmrec/ Marine energy systems will likely utilize composites tominimize corrosion/maintenance issues

Overview:Energy Applications: TidalWhat is optimal structural configuration?A generator akin to anaxial tube fan?(www.openhydro.com)A generator akin to a windmill(or aircraft propeller)?(www marineturbines com)(www.marineturbines.com)

Overview:Energy Applications: TidalTidal energy farms envisionedwww.marineturbines.com