HANDBOOK OF COMPOSITES978-1-4615-6389-1...HARRY W. DURSCH Boeing Defense and Space Group, PO Box...
Transcript of HANDBOOK OF COMPOSITES978-1-4615-6389-1...HARRY W. DURSCH Boeing Defense and Space Group, PO Box...
HANDBOOK OF COMPOSITES
HANDBOOKOF COMPOSITES
SECOND EDITION
Edited by
S.T. Pe ters Process Research, Mountain View, California, USA
la ni SPRINGER-SCIENCE+BUSINESS MEDIA, B.V.
First edition 1982
Second edition 1998
© 1998 Springer Science+Business Media Donlrecht Originally published by Chapman & Hall in 1998 Softcover reprint ofthe hardcover 2nd edition 1998 Thomson Science is a division of International Thomson Publishing
Typeset in 10/12 pt Palatino by GreenGate Publishing Services, Tonbridge, Engiand
ISBN 978-0-412-54020-2 ISBN 978-1-4615-6389-1 (eBook) DOI 10.1007/978-1-4615-6389-1
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publishers. Applications for permission should be addressed to the rights manager at the London address of the publisher.
The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannat accept any legal responsibility or liability for any errors or omissions that may be made.
A catalogue record for this book is available from the British Library
CONTENTS
Contributors
Preface
About the editor
Foreword
Acknowledgements
Introduction, composite basics and road map S.T. Peters
1 Overview of composite materials Theodore]. Reinhart
PART ONE: BASIC MATERIALS Polymeric matrix systems
2 Polyester and vinyl ester resin Frank A. Cassis and Robert C. Talbot
3 Epoxy resins L.S. Penn and H. Wang
4 High temperature resins Hugh H. Gibbs
5 Speciality matrix resins David A. Shimp
6 Thermoplastic resins Lars A. Berglund
Reinforcements and composites
7 Fiberglass reinforcement Dennis J. Vaughan
ix
xv
xvi
xvii
xviii
1
21
34
48
75
99
115
131
vi Handbook of composites
8 Boron, high silica, quartz and ceramic fibers 156 Anthony Marzullo
9 Carbon fibers 169 Khalid Lafdi and Maurice A. Wright
10 Organic fibers 202 Linda L. Clements
11 Particulate fillers 242 Harry S. Katz
12 Sandwich construction 254 Andrew C. Marshall
13 Metal matrix composites 291 VJ. Kostikov and V.S. Kilin
14 Ceramic composites 307 M.F. Amateau
15 Carbon-carbon composites 333 John D. Buckley
PART TWO: PROCESSING METHODS General composites and reinforced plastics
16 Hand lay-up and bag molding 352 D.R. Sidwell
17 Matched metal compression molding of polymer composites 378 Enamul Haque and Burr (Bud) L. Leach
18 Textile preforming 397 Frank K. Ko and Ceorge W. Du
19 Table rolling of composite tubes 425 John T. Kanne and Jerome S. Berg
20 Resin transfer molding 433 Lihwa Fong and S.C. Advani
21 Filament winding 456 Yu.M. Tarnopol'skii, S.T. Peters, A.I. Bei!,
22 Fiber placement 476 Don O. Evans
23 Pultrusion 488 Brian A. Wilson
24 Processing thermoplastic composites 525 James L. Throne
Advanced composites
25 Tooling for composites Jerry L. Cadden and Paul F. Sadesky
26 Consolidation techniques and cure control Zhong Cai and Timothy Gutowski
27 Composite machining Kent E. Kohkonen and Nitin Potdar
28 Mechanical fastening and adhesive bonding D. W. Oplinger
29 Surface preparations for ensuring that the glue will stick in bonded composite structures L.J. Hart-Smith, D. Brown and S. Wong
PART THREE: DESIGN AND ANALYSIS
30 Laminate design Jocelyn M. Seng
31 Design of structure with composites F.J. Schwan
32 Analysis methods v.v. Vasiliev
33 Design allowables substantiation Christy Kirchner Lapp
34 Mechanical tests Yu.M. Tamopol'skii and v.L. Kulakov
PART FOUR: ENVIRONMENTAL EFFECTS
35 Durability and damage tolerance of fibrous composite systems Ken Reifsnider
36 Environmental effects on composites Ann F. Whitaker, Miria M. Finckenor, Harry W. Dursch, R.c. Tennyson and Philip R. Young
37 Safety and health issues Jennifer A. Heth
38 Nondestructive evaluation methods for composites Thomas S. Jones
39 Repair aspects of composite and adhesively bonded aircraft structures Anton L. Seidl
40 Reuse and disposal Harry E. Pebly
Contents vii
556
576
596
610
667
686
709
736
758
778
794
810
822
838
857
883
viii Handbook of composites
PART FIVE: APPLICATIONS
41 Land transportation applications Douglas L. Denton
42 Marine applications Wayne C. Tucker and Thomas Juska
43 Commercial and industrial applications of composites Stewart N. Loud
44 Composite biomaterials Shalaby W. Shalaby and Robert A. Latour
45 Scientific applications of composites Vicki P. McConnell
46 Construction Ever J. Barbero
47 Aerospace equipment and instrument structure Gary C. Krumweide and Eddy A. Derby
48 Aircraft applications Richard N. Hadcock
49 Composites in the sporting goods industry Brian E. Spencer
APPENDICES
Appendix A Typical properties for advanced composites Kenneth R. Berg
Appendix B Specifications and standards for polymer composites Frank T. Traceski
Index
905
916
931
957
967
982
1004
1022
1044
1053
1059
1069
CONTRIBUTORS
SURESH G. ADVANI Department of Mechanical Engineering, University of Delaware, Spencer Laboratory, Newark, DE 19716, USA
MAURICE F. AMATEAU Applied Research Laboratory, Pennsylvania State University, PO Box 30, State College, PA 16804, USA
EVER J. BARBERO 315 Engineering Science Building, West Vll'ginia University, Morgantown, WV 26506-6106, USA
A.I. BElL' Institute of Polymer Mechanics, Latvian Academy of Sciences, 23 Aizkraukles Street, Riga LV-I006, Latvia
JEROME S. BERG True Temper Sports, 5421 Avenida Encinas, Suite G, Carlsbad, CA 92008, USA
KENNETH R. BERG Riggs Corporation, 837 Agate Street, Medford, OR 97501, USA
LARS A. BERGLUND Lulea University of Technology, SE-971 87 Lulea, Sweden
D.BROWN Boeing Commercial Airplane Group, Douglas Products Division, Mail Stop DOOI-0018, Long Beach, CA 90846, USA
JOHN D. BUCKLEY 23 East Governor Drive, Newport News, VA 23602, USA
JERRY L. CADDEN C & S Technologies, 42759 Mountain Shadow, Murrieta, CA 92562, USA
ZHONG CAl (deceased) 4180 Berkeley Creek Drive, Duluth, GA 30136, USA
x Handbook of composites
FRANK A. CASSIS FAC Associates, 1150 N. Mountain, Suite 102B, Upland, CA 91786, USA
LINDA L. CLEMENTS C & C Technologies, PO Box 1089, Dayton, NY 89403, USA
DOUGLAS L. DENTON Chrysler Corporation, CIMS 482-00-13, 800 Chrysler Drive, Auburn Hills, MI 48326-2757, USA
EDDY A. DERBY Composite Optics, 9617 Distribution Ave, San Diego, CA 92121, USA
GEORGEW.DU Principal Engineer, 16331 Bay Vista Drive Clearwater, FL 34620, USA
HARRY W. DURSCH Boeing Defense and Space Group, PO Box 3999, Mail Stop 73-09, Seattle, WA 98124-2846, USA
DONO. EVANS Cincinnati Milacron, 4701 Marburg Avenue, Cincinnati, Ohio 45209, USA
MIRIA M. FINCKENOR EH12 Bldg 4711, Marshall Space Flight Center, AL35812, USA
LIHWAFONG BLKG5, Nanyang Avenue, Singapore 63616
HUGH H. GIBBS Polycomp Consulting, Inc., 25 Crestfield Road, WIlmington, DE 19810, USA
TIMOTHY GUTOWSKI Department of Mechanical Engineering, Massachusetts Institute of Technology, Bldg 35-234, Cambridge, MA 02139, USA
RICHARD N. HADCOCK 6 Sue Circle, Huntington, NY 11743, USA
ENAMUL HAQUE Azdel, Inc., Technology Center, 658 Washburn Switch Road, Shelby, NC 28151-2284, USA
L.J. HART-SMITH Boeing Commercial Airplane Group, Douglas Products Division, Mail Stop 0800-0019, 4000 Lakewood Boulevard, Long Beach, CA 90846, USA
JENNIFER HETH Cytec Fiberite, 501 W. Third Street, Winona, MN 55987-2854, USA
THOMAS S. JONES Industrial Quality, Inc., 640 E. Diamond Ave., Suite C, Gaithersburg, MD 20877, USA
THOMAS JUSKA Naval Surface Warfare Center, Carderock Division, Structures and Composites Department, Bethesda, MD 20084-5000, USA
JOHN T. KANNE 2201 Johnson Road, Memphis, TN 38139, USA
HARRY S. KATZ Utility Development Corporation, 112 Naylon Avenue, Livingston, NJ 07039, USA
V.S. KILIN Niigrafit Institute, 2 Electrodonaya Street, Moscow, 111524, Russia
FRANKK.KO Drexel University, Fibrous Materials Research Laboratory 27-439, Philadelphia, PA 19104, USA
KENT E. KaHKONEN Brigham Young University, 435 CTB Technology Department, Provo, ur 84602, USA
VALERY I. KOSTIKOV Niigrafit Institute, 2 Electrodonaya Street, Moscow, 111524, Russia
GARY C. KRUMWEIDE Composite Optics, 9617 Distribution Avenue, San Diego, CA 92121, USA
v.1. KULAKOV
Contributors xi
Institute of Polymer Mechanics, Latvian Academy of Sciences, 23 Aizkraukles Street, Riga LV-1006, Latvia
KHAUD LAFDI Center for Advanced Friction Studies, Southern lllinois University at Carbondale, Carbondale, IL 62901-4343, USA
CHRISTY KIRCHNER LAPP 1412 Bellingham Way, Sunnyvale, CA 94087, USA
ROBERT A. LATOUR Clemson University, Clemson, SC 29634, USA
BURR 1. LEACH Cambridge Industries, 1700 Factory Avenue, Marion, IN 46952, USA
STEWART N. LOUD Composites Worldwide Inc., 991 Lomas Santa Fe Drive, C469, Solana Beach, CA 92075-2125, USA
xii Handbook of composites
VICKI P. MCCONNELL Ray Publishing, Independence Street, Suite 270, Wheat Ridge, CO 80033, USA
ANDREW C. MARSHALL Marshall Consulting, 720 Appaloosa Drive, Walnut Creek, CA 94596, USA
ANTHONY MARZULLO 39 Harold Street, Cos Cob, CT 06807-2132, USA
OONALD W. OPLINGER Federal Aviation Administration, Wm. J. Hughes Technical Center AAR-431, Atlantic City, International Airport, NJ 08405, USA
HARRY E. PEBLY 198 Center Grove Road, Randolph, NJ 07869, USA
LYNNS.PENN Department of Chemical and Materials
Engineering, 177 Anderson Hall, University of Kentucky, Lexington, KY 40506-0046, USA
S.T. PETERS Process Research, 925 Sladky Avenue, Mountain View, CA 94040-3625, USA
NITIN POTDAR Brigham Young University, 435 CTB Technology Department, Provo, UT 84602, USA
KENNETH REIFSNIDER Virginia Polytechnic Institute and State
University, Patton Hall 120, Blacksburg, VA 24061-0219, USA
THEOOORE J. REINHART 345 Forrer Boulevard, Dayton, OH 45419-3238, USA
PAUL F. SADESKY C & S Technologies, 23547 Mountain Court, Murrieta, CA 92562, USA
FRANK J. SCHWAN 36671 Montecito Drive, Fremont, CA 94536, USA
ANTON L. SEIDL 18941 Mellon Drive, Saratoga, CA 95070, USA
JOCELYN M. SENG Owens Corning Science and Technology
Center, 2790 Columbus Road, Granville, OH 43023-1200, USA
SHALABY W. SHALABY Clemson University, 301 Rhodes Res., Clemson, SC 29634, USA
DAVIDA. SHIMP PO Box 974, Prospect, KY 40059, USA
DONALD R. SIDWELL 44609 Grove Lane, Lancaster, CA 93534-2833, USA
BRIAN E. SPENCER Spencer Composite Corporation, 3220 Superior Street, PO Box 4377, Lincoln, NE 68504-0377, USA
ROBERT C. TALBOT 7199 Lorine Court, Columbus, OH 4323~5125, USA
YU.M. TARNOPOL'SKll Institute of Polymer Mechanics, Latvian Academy of Sciences, 23 Aizkraukles Street, Riga LV-1006, Latvia
R.c. TENNYSON University of Toronto, Institute for Aerospace Studies, 4925 Dufferin Street, Downsview, Ontario, Canada M3H 5T6
JAMES L. THRONE Sherwood Technologies, Inc., 158 Brookside Boulevard, Hinckley, OH 44233-9676, USA
FRANK TRACESKI Department of Defense, 5203 Leesburg Pike Suite 1403, Falls Church, VA 22041, USA
Contributors xiii
WAYNE C. TUCKER Naval Undersea Warfare Center, PO Box 86, Exeter, RI 02822, USA
V. V. VASILIEV Moscow State University, 14-1-110 Podolskih Kursantov Street, Moscow 113545, Russia
DENNIS J. VAUGHAN 146 Longview Drive, Anderson, SC 29621, USA
H.WANG Department of Chemical and Materials
Engineering, 177 Anderson Hall, University of Kentucky, Lexington, KY 40506-0046, USA
ANN F. WHITAKER EH01 Bldg 4612, Marshall Space Flight Center, AL35812, USA
BRIAN A. WILSON Wilson Composite Group, 6611 Folsom-Auburn Road, Suite C, Folsom, CA 95630, USA
S.WONG Boeing Commercial Airplane Group, Douglas Products Division, Mail Stop DOOl-0018, Long Beach, CA 90846, USA
xiv Handbook of composites
MAURICE A. WRIGHT Center for Advanced Friction Studies, Southern lllinois University at Carbondale, Carbondale, IL 62901-4343, USA
PHILIP R. YOUNG Emory & Henry College, Department of Chemistry, Emory, VA 24327, USA
PREFACE
Today, fiber reinforced composites are in use in a variety of structures, ranging from spacecraft and aircraft to buildings and bridges. This wide use of composites has been facilitated by the introduction of new materials, improvements in manufacturing processes and developments of new analytical and testing methods. Unfortunately, information on these topics is scattered in journal articles, in conference and symposium proceedings, in workshop notes, and in government and company reports. This proliferation of the source material, coupled with the fact that some of the relevant publications are hard to find or are restricted, makes it difficult to identify and obtain the up-to-date knowledge needed to utilize composites to their full advantage.
This book intends to overcome these difficulties by presenting, in a single volume, many of the recent advances in the field of composite materials. The main focus of this book is on polymeric matrix, metal matrix, and ceramic matrix composites. The book treats a wide range of subjects. The topics, presented in 49 chapters and two appendices include:
• overview of composite material systems and products;
• properties of different component (fiber, matrix, filler) materials;
• manufacturing techniques; • analysis and design; • testing; • mechanically fastened and bonded joints; • repair; • damage tolerance; • environmental effects; • health, safety, reuse, and disposal; • applications in:
- aircraft and spacecraft; - land transportation; - marine environments; - biotechnology; - construction and infrastructure; - sporting goods.
Each chapter, written by a recognized expert, is self-contained, and contains many of the 'state-of-the-art' techniques reqUired for practical applications of composites. Thus, this book should serve as a useful source of information for practicing engineers and specialists, as well as for workers new to this field.
George S. Springer
ABOUT THE EDITOR
S.T. Peters was previously a fellow engineer with Westinghouse Electric Corporation, Marine Division prior to devoting full time to composite and materials and processing consulting for his own company, Process Research, in Mountain View, CA. He has written many articles on composites and filament winding, a book on filament winding, edited one previous book and holds several patents on winding techniques and composite joints.
He is a private consultant with worldwide clients and has presented tutorials on composites to many audiences, including the US Navy and NASA, several technical societies and two universities. He is a licensed professional engineer in the state of California, a member of ASM, and the composites division of SME and has been elected a fellow of SAMPE.
FOREWORD
Composites have emerged as a valuable class of engineering materials because they offer many attributes not attainable with other materials. Light weight, coupled with high stiffness, and selectable properties have fostered their use for many years in satellites, high performance aircraft and world class sailboats as well as submarines. Now, these materials demonstrate their worth in the mundane, but equally as demanding, consumer, infrastructure, and sporting goods arenas. However, the transition to many of these consumer and infrastructure-relat¢d arenas has been slow, primarily due to the l,ack of understanding, the lack of validated data, absence of design allowables, lack of clear guidelines, limited hands-on experience, low confidence and less than optimum supplier data sheets. It is hoped that this book, crafted by well known contributors, pre-eminent in their field, members of international universities, industrial research organizations, and government labs will remedy some of these weak areas and that this edition will continue as the primary reference in the composites field and as basic a text for educational uses as was the first edition.
The editor of the first edition, George Lubin, was a valued mentor to many, including the present editor. This book carries on the legacy he started: that of a compact but thorough sourcebook, with validated, useful data to increase understanding, incorporating application guidelines, fabrication methods and tradeoffs, basic polymer information and design recommendations. The successful, cost-effective fabrication of composite structures requires utmost cooperation between the various design and manufacturing specialties
and is one of the prime drivers for' concurrent engineering'. The needs of concurrent engineering require all contributors to a successful composite structure design to have some knowledge of composites. It is hoped that this handbook will facilitate the acquisition of that knowledge.
There is little change in scope or objectives from the first edition, but many changes in content. Organic matrix composites are still highlighted and a limited treatment of metal matrix, carbon and ceramic matrix composites, as well as treatment of the new polymers, including the thermoplastic materials have been added.
The treatment of processing methods has been expanded for reader convenience, doubling the previous number of chapters. The structural efficiency of a composite structure is often determined by its joints, not by its basic structure. Thus, an extensive treatment of composite surface treatment, mechanical fastening, and adhesive bonding, which continue to be important, sometimes vexing areas of concern in composite structure fabrication, have been added.
The analysis section has been expanded with chapters dealing with laminate design, composite structure design and a new, important subject, design allowables substantiation.
There are new chapters on repair, safety and reuse of composites as well as chapters on the applications of composites to medical, construction and sporting goods uses that reflect current concerns and important new uses for composite materials.
S.T. Peters
ACKNOWLEDGEMENTS
As with any large undertaking there is a sup- approach to resolving problems. Thanks also porting group of people without whose help go to Mr Frank Hell and Dr Alvin Nakagawa the objective would not be met. I wish to of Westinghouse Electric, Marine Division acknowledge my wife, Lynn, for her help in (now Norton Grumman) for their editorial deciphering and rewriting some of the articles and review help. I also wish to thank Dr Linda and for enduing my sometimes uncivil Clements for her advice and support.