By:Shankaranaray

ananNitin Meena

Rajat PradhanYogesh Jagtab

Sukhdev 1

COMPOSITESMANUFACTURING

TECHNOLOGY

Contents

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Introduction to Composites.Manufacturing Technology.Case Study – Boeing 787

Introduction to composites

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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.

Components of composite materials

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Reinforcement: fibers

GlassCarbonOrganicBoronCeramicMetallic

Matrix materials

PolymersMetalsCeramics

Interface

Bonding surface

Characteristics of composites

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Classification of composites

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First Level (Matrix Material)

Metal Matrix Composites.Ceramic Matrix Composites.Polymer Matrix composites.

Second Level (reinforcement form)

ParticulateWhiskerContinuous FiberWoven Composites

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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.

Composites – Metal Matrix

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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.

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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.

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Application of Composites

Pedestrian bridge in Denmark, 130 feet long (1997)

Swedish Navy, Stealth (2005)

Application of Composites

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COMPOSITES MANUFACTURING

TECHNOLOGY

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Manufacturing Processes

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Hand Lay-upVacuum bagging/autoclaveCompression MouldingLiquid Resin Moulding.PultrusionFilament WindingInjection MouldingThermoplastics processingAutomated Tape Laying

Hand Lay-up

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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.

Spray Lay-up

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Glass fibers chopped up Resin, catalyst, & fibers sprayed onto a

mold Cures at ambient temperature and

atmospheric pressure

Moulds

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Vacuum Bag Molding

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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.

Vacuum bag assembly

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Autoclave Molding

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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

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

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Compression Molding

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VARTM and RTM

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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

Resin transfer moulding (RTM)

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RTM - Applications

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Pultrusion process

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Pultrusion Applications

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Filament Winding

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Filament Winding Machines

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Filament Winding - Applications

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Thermoplastics- Injection Molding

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Roll Forming

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Matched Die Forming

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Hydroforming

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Tape Laying

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Advantages / Disadvantages

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CASE STUDY – BOEING 787

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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

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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

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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

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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

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Automated Tape Laying machine- Used to the layup of the flight deck floor

Fuselage Unloader- Used to unload fuselage sections from Dreamlifter

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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?

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Application of Composites in Aircraft Industry

20% more fuel efficiency and 35,000 lbs. lighter

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Advantages of Composites1) Higher Specific Strength (strength-to-weight ratio)

2) Design flexibility3) Corrosion resistance4) Low Relative investment5) Durability

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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.

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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. 

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Disadvantages of CompositesIn November 1999, America’s Cup boat “Young America” broke in two due to debonding face/core in the sandwich structure.

THE FUTURE OF COMPOSITES

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Future uses of structural composites: Automotive Industry

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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

Nanocomposites

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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

Nanocomposite: Under a microscope

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Carbon

Nanotubes

Polymer

Matrix

Nanocomposite Examples

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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

Nanocomposites in BioMed

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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