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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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
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.
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
ME 7502 Introduction - Dr. Brian J. Sullivan
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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
...+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
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