Composite Materials Handbook Overview

Gerry Flanagan

Materials Sciences Corporation

What is the Composite Materials Handbook?

"Develop world-class engineering handbooks for structural applications of composite materials. These handbooks will include standards for test/characterization methods, statistics and databases, as well as guidelines for processing, design and analysis.

All information contained in the Mil-17 Composite Material Handbooks is developed by working groups comprised of experts from industry, government, and academia from around the world, and subjected to a rigorous review process prior to its official release."

"Develop world-class engineering handbooks for structural applications of composite materials. These handbooks will include standards for test/characterization methods, statistics and databases, as well as guidelines for processing, design and analysis.

All information contained in the Mil-17 Composite Material Handbooks is developed by working groups comprised of experts from industry, government, and academia from around the world, and subjected to a rigorous review process prior to its official release."

Vision Statement

History

1978 Revitalized Coordination Group Formed

1988 First release of Vol. 1

1993 MMC Coordination Group Formed

1996 CMC Coordination Group Formed

1998 Began having joint meetings with ASTM D30

2002 Release of Volumes 1F, 2F, 3F, 4A, 5

2002 Commercial publication through ASTM

2004 Joint meetings with CACRC, SAE P-17

2006 Secretariat contract moved from Army to FAA

2006 Roadmap to release G established

CMH-17

US Army no longer supports military handbooks The FAA is the primary sponsor of the handbook Secretariat contract moved from the Army to the FAA

– Interim contract through NCAMP DoD review of handbook no longer required Requirement to post free copies on DoD achieve site no longer holds The FAA will hold the copyright to the handbook and data Name change to “Composite Materials Handbook-17

Draft of possible new logo

Approval Procedures

Working Group internally makeswriting assignments and generatesa draft. May iterate within groupuntil acceptable

Working Group internally makeswriting assignments and generatesa draft. May iterate within groupuntil acceptable

Sections submitted to Secretariat for inclusion in Yellow PagesSections submitted to Secretariat for inclusion in Yellow Pages

Yellow pages go to all “members” for technical commentYellow pages go to all “members” for technical comment

Secretariat tries to resolve comments. May make editorial changes.

Secretariat tries to resolve comments. May make editorial changes.

Yellow pages go to Coordination. Final technical comments may be resolved at meeting. If not accepted, return to WG for revision.

Yellow pages go to Coordination. Final technical comments may be resolved at meeting. If not accepted, return to WG for revision.

Entire handbook release draft goes to DoD Coordination for reviewEntire handbook release draft goes to DoD Coordination for review

PublicationPublication

Data Process

Data Source- Material supplier- User- Government program

Secretariat- Data documentation- Data analysis

Released Data

Data Review Working Group

- Detail review- Cross section of

industry suppliers, users, academia, government

Additional Info

Needed

Full Handbook Group & DoD

Review

8 + Months

Structure of the Handbook

Vol. 1 Polymer Matrix Composites: Guidelines for Characterization of Structural Materials

Vol. 2 Polymer Matrix Composites: Material Properties Vol. 3 Polymer Matrix Composites: Materials Usage, Design and

Analysis Vol. 4 Metal Matrix Composites Vol. 5 Ceramic Matrix Composites Vol. 6 Structural Sandwich Composites (Planned)

Volume 1: Polymer Matrix Composites Guidelines for Characterization of Structural Materials

1. Objectives

2. Guidelines for Property Testing of Composites

3. Evaluation of Reinforcement Fibers

4. Matrix Characterization

5. Prepreg Materials Characterization

6. Lamina and Laminate Characterization

7. Structural Element Characterization

8. Statistical Methods

Volume 1 documents material characterization data development methodology guidelines adaptable to a wide variety of needs, as well as specific requirements to be met by data published in the handbook

Volume 2: Polymer Matrix CompositesMaterial Properties

1. General Information

2. Fiber Properties

3. Matrix Properties

4. Carbon Fiber Composites

5. Aramid Fiber Composites

6. Glass Fiber Composites

7. Boron Fiber Composites

8. Alumina Fiber Composites

9. Silicon Carbide Fiber Composites

10 Quartz Fiber Composites

Appendix MIL-HDBK-17A Data

Volume 3: Polymer Matrix CompositesMaterials Usage, Design and Analysis

1. General Information

2. Materials and Processes

3. Quality Control of Production Materials

4. Building Block

5. Design and Analysis

6. Structural Behavior of Joints

7. Damage Resistance, Durability and Tolerance

8. Supportability

9. Structural Reliability

10.Thick Section Composites

11.Environmental Management

12.Lessons Learned

Volume 4 Metal Matrix Composites

1. Guidelines

1.1 General Information

1.2 Introduction to MMC Materials

1.3 Test Plans for Material Characterization

1.4 Composite Testing and Analytical Methods

1.5 Intermediate Forms Testing and Analytical Methods

1.6 Fiber Testing ..

1.7 Fiber Sizing Testing ..

1.8 Fiber Coatings, Interfaces, and Interphases Testing ..

1.9 Matrix Testing ..

1.10 Structural Sensitive Properties Characterization

1.11 Analysis of Data

2. Design Guidelines for Metal Matrix Materials2.1 General Information2.2 Use of Data2.3 Structural Design and Analysis2.4 Design Guidelines - Joining2.5 Applications Case Studies

3. Materials Properties Data3.1 General Information3.2 Reinforcement Properties (Typical)3.3 Properties of Matrix Materials (Typ)3.4 Fiber Coating Properties (Typ)3.5 Aluminum Matrix Composite Prop.3.6 Copper Matrix Composite Prop.3.7 Magnesium Matrix Composite Prop.3.8 Titanium Matrix Composite Prop.3.9 Other Matrix Composites

Volume 5 Ceramic Matrix Composites

Part A. Introduction and Guidelines1. MIL-17 Guidelines and Procedures2. Introduction, History and Overview3. Processing, Characterization, and

Manufacturing4. Quality Control of Final Products5. Applications, Case Histories, and

Lessons Learned.Part B. Design and Supportability

6. Design and Analysis7. Supportability

Part C. Testing8. Thermo-Mechanical-Physical Test

Methods, Overview9. Material Testing & Characterization

for Submission of Data to MIL-HDBK-17

10. Evaluation of Reinforcements

11. Evaluation of Matrix Materials

12. Evaluation of Interface Materials

13. Evaluation of Composites

14. Subcomponent Testing

15. Machining and Grinding

16. Statistical Methods

Part D. Data Requirements and Data Sets

17. Data Submission, Format, and Requirements

18. CMC Property Data

Appendix A. Typical CMC Data

Release Status

CURRENTLY AVAILABLE

– Volumes 1-3 Release F (PMC)

– Volume 4 Release A (MMC)

– Volume 5, Initial Release (CMC)

Group is now working on next version

– Between-release versions available to group members as a draft working copy on website

– Major changes in Volumes 1-3

– New Volume 6

Snapshot of Carbon Materials Available in Release F

The Composite Handbook Organization

SecretariatMaterials Sciences Corp

Specialized Data Develop.Gene Camponeschi, NAVSEA

Dana Granville, ARL

Data ReviewJohn Tomblin, Wichita State Univ

Peter Shyprykevich, FAA

Materials & ProcessesMargaret Roylance, Natick - ArmyDaniel Ruffner, Boeing Helicopter

StatisticsJohn Adelmann, Sikorsky.

SupportabilityBud Westerman, BoeingMr. Lawrence Coulter , USAF

TestingRich FIelds, Lockheed MartinJohn Moylan, Delsen Testing

PMC Coordination GroupLarry Ilcewicz, FAADana Granville, ARL

GuidelinesCarl Rousseau, LM/Aero-FWSteve Ward, SW Composites

Handbook ChairmenLarry Ilcewicz, FAADana Granville, ARL

Executive Group(WG Chairs)

Damage Tolerance

CMC,MMCCoordination

Groups

Per

man

ent

Wo

rkin

g G

rou

ps

Sandwich CompositesLarry Gintert, CTC

Melanie Violette, Raytheon

Structural Safety

~120 volunteers attend meetings

> 200 remain on roster

SpacecraftMark Kistner, AFRL

Thomas Wong, T. Wong Consultants

Safety ManagementBjorn F. Backman,

Structured ResearchLarry Ilcewicz, FAA

CrashworthinessPaolo Feraboli, U. of Wa.

Airworthiness

Analysis Design

Debond & Delam

Activities and Focus of the Working Groups

The objective of the Materials and Processes Working Group is to provide guidelines, descriptions and case studies of material and processing options for the characterization and fabrication of polymer matrix composite materials

The primary goal of the Guidelines Working Group is to develop and document generic guidance information and data which is essential for the adequate design, certification or qualification, and production of composite parts and assemblies.

Guidelines

Materials and Processes

Working Groups (Cont.)

The objectives of the Data Review Working Group are as follows:• To provide the final technical/editorial review of all data.• To provide a review of the application of the data documentation

requirements to the actual data being supplied. • To develop formats for data presentation in the handbook. • To establish the data documentation requirements for the handbook

Data Review

The Statistics Working Group analyzes and/or develops statistical procedures for composite material evaluation and quality control, and provides other statistical support to the Handbook as directed by the Guidelines Working Group. The Statistics working group spans the three coordination groups with co-chairs for metal matrix and ceramic matrix composites

Statistics

Working Groups (Cont.)

The objective of the Supportability Working Group is to provide useful guidelines in the design for and design of repairs for composite structures. The group recently wrote a supportability chapter (Volume 3, Chapter 8) for inclusion in MIL-HDBK 17.

The objectives of the Testing Working Group are as follows:• To offer descriptive and guidance information relating to the usage of

chemical, physical and mechanical test methods for polymer matrix composites and their constituents.

• Inform the reader of advantages and shortcomings of the various methods used in the industry

• Provide a basis for test method selection • To identify specific test methods to be used when data is submitted to MIL-

HDBK-17 for consideration for inclusion in Volume 2 of the handbook.

Testing

Supportability

Working Groups, (Cont.)

Composites for Space

Specialized Data Development

The Composites for Space Working Group addresses the special concerns related to the application of polymer matrix composites in a space environment, including the introduction of additional physical property measurements into the handbook. In addition, the group will encourage the inclusion of material property data of interest to the spacecraft community

Specialized Data Development deal with the issues that arise in non-traditional forms of composite materials including textiles, 3-D reinforcements, and thick section composites. In addition, the group deals with the particular technical issues related to non-aerospace applications.

Working Groups, (Cont.)

The Sandwich Working Group is responsible for the creation of a Structural Sandwich Composites Volume as part of MIL-HDBK-17. The primary source for this volume will be MIL-HDBK-23. The group will review and revise the material in MIL-HDBK-23. New sections may be created to reflect technology changes since the last revision of MIL-HDBK-23

Sandwich

Crashworthiness

The newly formed Crashworthiness Working Group will provide the support for the development of a new, self-contained section of the handbook on composite Crashworthiness and Energy Management for vehicle safety certification. The Working Group will also attempt to address the needs of the composites and vehicle safety community at large, and to provide a unique forum of discussion for those working in industry, research institutions, and government agencies.

Working Groups (Cont.)

The Safety Management Working Group is responsible for the Volume 3 Chapter entitled “Structural Safety”. Recognizing the need for innovation with new technologies such as composite materials, the Safety Management WG is responsible for managing the elements of vehicle structural safety, which include requirements, design criteria, quality control, damage considerations, inspection, education and continuous service data monitoring throughout a vehicle's life cycle. Safety management relies on integration of the efforts by design, manufacturing, maintenance and operations disciplines. It is also driven by service experience and an international mandate to improve safety statistics as future fleets of a given vehicle type expand.

The Safety Management WG currently has three Task Groups: 1) Structural Safety, 2) Debond and Delamination and 3) Damage Tolerance. It's current emphasis is on the safety of composite aviation and aerospace vehicle applications.

Safety Management

71 Organizations Represented at Last PMC Meeting. 115 Attendees

ABAQUS, Inc. DaimlerChrysler Corporation Lockheed Martin The Advanced Composites Group

Abbott Aerospace Composites Delsen Testing Laboratories, Inc.

Materials Sciences Corporation

The University of British Columbia

AFRL/MLBC DSTL Physical Sciences Dept. NASA Langley Research Center Toray Carbon Fibers America

American Bureau of Shipping DuPont NASA/MSFC Toyota ABDO

Bell Helicopter Textron Embraer - Empresa Brasileira de Aeronautica S.A. National Institute of Aerospace Transport Canada (MOT)

Bentley Motors Limited Engenuity Limited National Research Council Canada, Govt. of Canada U.S. Army Research Lab

BFGoodrich Aerospace - Engineered Polymer Products Euro-Composites Corporation

Newport Adhesives and Composites

U.S. Army Soldier Systems Center

Boeing European Aviation Safety Agency (EASA) NSE Composites

University of California at Santa Barbara

Boeing Comm. Airplane FAA NSWCCD University of California, Irvine

Boeing Helicopter Mesa FiberCote Industries, Inc. Oak Ridge National Laboratory

University of California, Santa Barbara

Bombardier Aerospace Friedman Research Corp. Politecnico di Milano University of Delaware Bristol Aerospace Ltd. GE Transportation Pratt & Whitney University of Utah Buttoncap Technical Services Inc.

Georgia Institute of Technology Raytheon Aircraft Company University of Washington

Composites Innovation Inc. Goodrich Aerostructures Spirit Aerosystems US Army Benet Laboratories, AMSRD-AAR-AEW-TA(B)

Concurrent Technologies Corporation Gougeon Brothers, Inc. Stanford University US Army RDECOM / TARDEC Consultant Gulfstream Aerospace Structured Research US Navy (NAVAIR)

Cytec Honda R&D Americas, Inc. SW Composites Wichita State University - NIAR

Japan Aerospace Exploration Agency (JAXA) Tenax America, Inc. Wyoming Test Fixtures, Inc.

Organizations at Recent MMC and CMC Meetings

Materials Sciences Corporation Air Force Research Lab/MLLMN Air Force Research Laboratory NASA-GRC Concurrent Technologies Corporation FMW Composite Systems, Inc.

P r a t t & W h itn e y R o c k e td y n e In c . N A S A G le n n R e s e a r c h C e n te r Te c h n o lo g y A s s e s s m e n t a n d T r a n s fe r In c . R o lls - R o y c e G a te w a y M a te r ia ls Te c h n o lo g y N A S A G le n n R e s e a r c h C e n te r S ta r f ir e S y s te m s , In c . G o o d r ic h C o r p o r a t io n - H ig h Te m p e r a tu r e C o m p o s ite s U n ite d Te c h n o lo g ie s R e s e a r c h C e n te r O a k R id g e N a t io n a l L a b o r a to r y R o lls - R o y c e C o r p o r a t io n B o e in g P h a n to m W o rk s S ta r f ir e S y s te m s , In c . G E E n e rg y P r a t t & W h itn e y O a k R id g e N a t io n a l L a b o r a to r y P r a t t & W h itn e y S o u th e r n I l l in o is U n iv e r s i t y C a r b o n d a le 3 Te x , In c . A F R L /P R T C C O I C e r a m ic s , In c . O a k R id g e N a t io n a l L a b o r a to r y G E A v ia t io n , C o m p o s ite s Te c h n o lo g y R o lls - R o y c e /L ib e r ty W o rk s O a k R id g e N a t io n a l L a b o r a to r y N A S A M a r s h a ll S p a c e F lig h t C e n te r S o la r T u r b in e s In c o r p o r a te d U n ite d Te c h n o lo g ie s R e s e a r c h C e n te r G E A v ia t io n Id a h o N a t io n a l L a b o r a to ry

MMC CMC

Member’s Web Site

https://www.mil17.org– Most recent draft of the handbook– Available in PDF format– Access to working group bulletin boards– Contact information for working group chairs– Upcoming meeting info including agendas, topics– Past meeting documents including presentations, minutes

– ACCESS• MIL-17 participants receive access free of charge with meeting

registration fee• Website access can also be purchased directly if attending the

meeting is not possible ($150 for 16 months)

Commercial Publication

ASTM Publishing offers the printed and CD-ROM versions of Volumes 1F, 2F, 3F, 4A, 5

– $110 per volume

– $550 for CD-ROM version (includes CES for MIL17 database)

– $650 for bundled version (5 volumes + CD)

www.astm.org

– Click on “Technical Publications”

– Search for:

“Composite Materials Handbook”

Becoming Involved

Get on the mailing list (handbook@materials-sciences.com) Attend Meetings

– Presentations• Industry status and practice• Technical talks on topics related to material allowables,

qualification, and design practice– Discussion and debates on current handbook topics– Affect the direction of the handbook

• Particularly looking for inputs from broader range of industries• Provide input of user needs and concerns

Become an active volunteer for one or more of the Working Groups– Be a contributor

Provide data

Meeting schedule

MIL-17 Coordination Groups currently meet every 8 months

Joint meeting with ASTM D30 every 2 years (October)

Alternating East Coast, West Coast sites

Schedule: Monday

Sheraton II Chicago I Chicago II

Monday

8:00 - 9:00Exec Planning    

7/17/2006 9:00 - 10:00

  10:00 - 10:45 PMC Coordination Intro to MIL-17  

  10:45 - 11:00 Break

  11:00 - 12:30

Statistics Airworthiness TGSpecialized Data

Development

  12:30 - 1:45 Lunch

  1:45 - 3:15 M&P Design TG Damage Tolerance TG

  3:15 - 4:45 M&P + Sandwich Debond/Delam TG Data Review

  4:45 - 5:00 Break

  5:00 - 6:00Crashworthiness Supportability Data Review

  6:00 - 7:00

Schedule: Tuesday

Sheraton II Chicago I Chicago II

Tuesday

8:00 - 9:00Crashworthiness

Structural Safety (Reliability) TG

NCAMP

7/18/2006 9:00 - 10:00

  10:00 - 10:15 Break

  10:15 - 11:15Sandwich Safety Management Statistics

  11:15 - 12:15

  12:15 - 1:30 Lunch

  1:30 - 2:30Sandwich Guidelines Testing

  2:30 - 3:30

  3:30 - 3:45 Break

  3:45 - 4:45P-17 + M&P Guidelines Spacecraft

  4:45 - 5:45

  6:00 - 7:30 MIL-HDBK-17 Social

Schedule: Wednesday

Sheraton II

Wednesday

8:00 - 9:00

PMC Coordination

7/19/2006 9:00 - 10:00

 10:00 - 10:15 Break

  10:15 - 11:15

Exec Planning

  11:15 - 12:15

Wednesday, 7/19/06, 1:00 p.m. to Friday, 7/21/06, 12:00 p.m.

  FAA Composite Damage Tolerance and Maintenance Workshop

Questions?