composites manufacturing technology
DESCRIPTION
Composites manufacturing technologyTRANSCRIPT
![Page 1: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/1.jpg)
By:Shankaranaray
ananNitin Meena
Rajat PradhanYogesh Jagtab
Sukhdev 1
COMPOSITESMANUFACTURING
TECHNOLOGY
![Page 2: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/2.jpg)
Contents
2
Introduction to Composites.Manufacturing Technology.Case Study – Boeing 787
![Page 3: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/3.jpg)
Introduction to composites
3
What is a composite Material ? Two or more chemically distinct materials
which when combined have improved properties over the individual materials.Example: Wood, Bamboo, Bricks.Composites are combinations of two materials in which one of the material is called the reinforcing phase, is in the form of fibers, sheets, or particles, and is embedded in the other material called the matrix phase.
![Page 4: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/4.jpg)
Components of composite materials
4
Reinforcement: fibers
GlassCarbonOrganicBoronCeramicMetallic
Matrix materials
PolymersMetalsCeramics
Interface
Bonding surface
![Page 5: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/5.jpg)
Characteristics of composites
5
![Page 6: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/6.jpg)
Classification of composites
6
First Level (Matrix Material)
Metal Matrix Composites.Ceramic Matrix Composites.Polymer Matrix composites.
Second Level (reinforcement form)
ParticulateWhiskerContinuous FiberWoven Composites
![Page 7: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/7.jpg)
7
Composites – Polymer MatrixPolymer matrix composites (PMC) and fiber reinforced plastics (FRP) are referred to as Reinforced Plastics. Common fibers used are glass (GFRP), graphite (CFRP), boron, and aramids (Kevlar). These fibers have high specific strength (strength-to-weight ratio) and specific stiffness (stiffness-to-weight ratio)
Matrix materials are usually thermoplastics or thermosets; polyester, epoxy (80% of reinforced plastics), fluorocarbon, silicon, phenolic.
![Page 8: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/8.jpg)
Composites – Metal Matrix
8
The metal matrix composites offer higher modulus of elasticity, ductility, and resistance to elevated temperature than polymer matrix composites. But, they are heavier and more difficult to process.
![Page 9: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/9.jpg)
9
Composites – Ceramic MatrixCeramic matrix composites (CMC) are used in applications where resistance to high temperature and corrosive environment is desired. CMCs are strong and stiff but they lack toughness (ductility)
Matrix materials are usually silicon carbide, silicon nitride and aluminum oxide, and mullite (compound of aluminum, silicon and oxygen). They retain their strength up to 3000 oF.
Fiber materials used commonly are carbon and aluminum oxide.
Applications are in jet and automobile engines, deep-see mining, cutting tools, dies and pressure vessels.
![Page 10: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/10.jpg)
10
Application of Composites
Pedestrian bridge in Denmark, 130 feet long (1997)
Swedish Navy, Stealth (2005)
![Page 11: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/11.jpg)
Application of Composites
11
![Page 12: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/12.jpg)
COMPOSITES MANUFACTURING
TECHNOLOGY
12
![Page 13: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/13.jpg)
Manufacturing Processes
13
Hand Lay-upVacuum bagging/autoclaveCompression MouldingLiquid Resin Moulding.PultrusionFilament WindingInjection MouldingThermoplastics processingAutomated Tape Laying
![Page 14: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/14.jpg)
Hand Lay-up
14
A Process wherein the application of resin and reinforcement is done by hand onto a suitable mould surface. The resulting laminate is allowed to cure in place without further treatment.
![Page 15: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/15.jpg)
Spray Lay-up
15
Glass fibers chopped up Resin, catalyst, & fibers sprayed onto a
mold Cures at ambient temperature and
atmospheric pressure
![Page 16: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/16.jpg)
Moulds
16
![Page 17: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/17.jpg)
Vacuum Bag Molding
17
Two-sided mold set. Shapes both surfaces of the panel. Lower side is a rigid mold Upper side is a flexible membrane or vacuum bag Bag made of silicone material or an extruded
polymer film. Performed at either ambient or elevated
temperature. Ambient atmospheric pressure acts upon the
vacuum bag. Most economical way uses venturi vacuum and air
compressor or a vacuum pump.
![Page 18: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/18.jpg)
Vacuum bag assembly
18
![Page 19: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/19.jpg)
19
![Page 20: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/20.jpg)
Autoclave Molding
20
Two-sided mold set Lower Side rigid mold Upper Side flexible membrane made from silicone
or an extruded polymer film Reinforcement materials can be placed manually
or robotically Include continuous fiber forms fashioned into
textile constructions Use of autoclave pressure vessel process generally performed at both elevated
pressure and elevated temperature elevated pressure facilitates a high fiber volume
fraction Elevated pressure yields low void content for
maximum structural efficiency
![Page 21: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/21.jpg)
Uses elevated pressure and temperature to consolidate plastic and fibers into a solid structure
Various range of sizes Small Laboratory Prototype models Aircraft and Large Application models
Used for high-performance parts with the
highest strength-to-weight ratios
Autoclaves
21
![Page 22: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/22.jpg)
Compression Molding
22
![Page 23: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/23.jpg)
23
![Page 24: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/24.jpg)
VARTM and RTM
24
Vacuum Assisted Resin Transfer Molding Sometimes a pump used to remove any air within the system Resins permeate through the material from the top
displacing air Uses low viscosity catalyzed resins injected into the piece Cures with low temperature and low pressure
![Page 25: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/25.jpg)
Resin transfer moulding (RTM)
25
![Page 26: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/26.jpg)
RTM - Applications
26
![Page 27: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/27.jpg)
Pultrusion process
27
![Page 28: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/28.jpg)
28
![Page 29: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/29.jpg)
29
![Page 30: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/30.jpg)
Pultrusion Applications
30
![Page 31: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/31.jpg)
Filament Winding
31
![Page 32: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/32.jpg)
Filament Winding Machines
32
![Page 33: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/33.jpg)
33
![Page 34: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/34.jpg)
Filament Winding - Applications
34
![Page 35: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/35.jpg)
Thermoplastics- Injection Molding
35
![Page 36: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/36.jpg)
Roll Forming
36
![Page 37: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/37.jpg)
Matched Die Forming
37
![Page 38: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/38.jpg)
Hydroforming
38
![Page 39: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/39.jpg)
Tape Laying
39
![Page 40: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/40.jpg)
Advantages / Disadvantages
40
![Page 41: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/41.jpg)
CASE STUDY – BOEING 787
41
![Page 42: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/42.jpg)
Boeing 787Benefits the of the 787 (aka.
“Dreamliner”)I. Light weight-
a. Fuel efficientb. Longer range than comparable
aircraft
II. Reduced maintenance costsa. $30-40 million in savings
i. High reduction in fatigueii. Highly corrosion resistant
42
![Page 43: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/43.jpg)
Boeing 787 III. Increased passenger comfort
a. Increase in cabin pressureb. Increased humidity
i. Result of high corrosion resistancec. Bigger windows due to increased strengthd. Less noise
i. Front engine cowl intake is made of a single piece of composite, reducing drag
IV. Decreased assembly time a. Parts arrive from suppliers as net-shape
b. Components are pre-installed in parts at supplier factory
43
![Page 44: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/44.jpg)
44
![Page 45: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/45.jpg)
45
![Page 46: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/46.jpg)
Boeing 787
Cost- Benefit Analysis of the Boeing 787
I. Boeing estimates that 787 will consume $5 million less in fuel on a comparable route than 767
a. Savings = Price of plane
II. Potentially longer lifea. Not proven yet, but likely due
to the high reduction in corrosion and fatigue
46
![Page 47: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/47.jpg)
Boeing 787Changes Boeing Has Made in Order to
Create a Composite AirplaneI. Composites are made elsewhere.
a. Attached in the factory using titanium hardware and adding carbon sheets where needed
II. Safety equipment a. Revamped to provide protection from carbon dust
II. New machines and equipmenta. Alignment machines to assemble
tubesi. Needed in order to attach
fuselage due to low flexibility of fuselage
47
![Page 48: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/48.jpg)
48
Automated Tape Laying machine- Used to the layup of the flight deck floor
![Page 49: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/49.jpg)
Fuselage Unloader- Used to unload fuselage sections from Dreamlifter
49
![Page 50: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/50.jpg)
Boeing 787Some difficulties and problems Boeing has encountered during this project, and how
have they been overcomeI. Estimating weights of composite parts very
difficulta. Current plane is overweight
i. Redesign parts to conform to specs
II. Problems detecting and repairing damage
a. Composites pose a great challenge to finding flaws and cracks
III. Value of components very high preceding machining
IV. How to recyclea. One time material use?
50
![Page 51: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/51.jpg)
51
Application of Composites in Aircraft Industry
20% more fuel efficiency and 35,000 lbs. lighter
![Page 52: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/52.jpg)
52
Advantages of Composites1) Higher Specific Strength (strength-to-weight ratio)
2) Design flexibility3) Corrosion resistance4) Low Relative investment5) Durability
![Page 53: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/53.jpg)
53
Disadvantages of Composites
The experience and intuition gained over the years about the behavior of metallic materials does not apply to composite materials.
properties in composites vary from point to point in the material. Most engineering structural materials are homogeneous.
Composites are heterogeneous
Composites are highly anisotropic
The strength in composites vary as the direction along which we measure changes (most engineering structural materials are isotropic). As a result, all other properties such as, stiffness, thermal expansion, thermal and electrical conductivity and creep resistance are also anisotropic. The relationship between stress and strain (force and deformation) is much more complicated than in isotropic materials.
![Page 54: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/54.jpg)
54
Disadvantages of CompositesComposites materials are difficult to inspect with conventional ultrasonic, eddy current and visual NDI methods such as radiography.
American Airlines Flight 587, broke apart over New York on Nov. 12, 2001 (265 people died). Airbus A300’s 27-foot-high tail fin tore off. Much of the tail fin, including the so-called tongues that fit in grooves on the fuselage and connect the tail to the jet, were made of a graphite composite. The plane crashed because of damage at the base of the tail that had gone undetected despite routine nondestructive testing and visual inspections.
![Page 55: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/55.jpg)
55
Disadvantages of CompositesIn November 1999, America’s Cup boat “Young America” broke in two due to debonding face/core in the sandwich structure.
![Page 56: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/56.jpg)
THE FUTURE OF COMPOSITES
56
![Page 57: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/57.jpg)
Future uses of structural composites: Automotive Industry
57
Today it is easy to be optimistic about the future use of composite materials in the automotive industry.Substitution of metals with composites not
unavoidable and automatic. Composite material applications will increase,
but they will never completely replace metals Composite materials have enormous potential
Industry will need to demonstrate advantages for each application and compete with advocates of metals
Designers should seek to work with both materials exploiting best characteristics for a given application
![Page 58: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/58.jpg)
Nanocomposites
58
Nanoparticulates (filler) introduced into a macroscopic sample material (matrix)
Percentage by weight (mass fraction) of the nanoparticulates can remain very low on the order of 0.5% to 5%
Nanocomposite may exhibit enhanced propertieselectrical and thermal conductivityoptical propertiesdielectric properties mechanical properties
stiffness Strength
…Or nanoparticles can impart new physical properties and behaviors to matrix (genuine nanocomposites or hybrids) flame retardancy accelerated biodegradability
![Page 59: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/59.jpg)
Nanocomposite: Under a microscope
59
Carbon
Nanotubes
Polymer
Matrix
![Page 60: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/60.jpg)
Nanocomposite Examples
60
Continuous Carbon Nanotube Reinforced Composites 3300% improvement in longitudinal modulus
under compressionup to 2100% improvement in damping capabilitycomposites with a random distribution of
nanotubes of same length and similar filler fraction provide 3x less effective reinforcement in composites.
Cyclics CBT resin nano-composite structure produces properties not previously possible with traditional engineering thermoplasticsThermoplastic with near water viscosityExtreme castabilityHeadquarted in Schenectady
![Page 61: Composites manufacturing technology](https://reader031.vdocuments.us/reader031/viewer/2022013107/54bcc30e4a795923428b4644/html5/thumbnails/61.jpg)
Nanocomposites in BioMed
61
Bio-mimicking artificial muscles or skins Soft tissue-like material can be made
into an electroactive polymer Don’t have to add mechanical motors
Composite of PMMA and hydroxyapatite w/ MWCNT can be used as next-gen bone cement
Biosensors using Sol-Gel technology