Composites 100 Years

8/13/2019 Composites 100 Years

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Two or more materials combined to

perform some useful purpose

Exhibits the best properties of theindividual materials plus additional

qualities that the individual materials do

not exhibit alone

Examples

Mud and straw

Steel-reinforced concrete

Fibers embedded in a plastic resin matrix

Oriented Strand Board (OSB)

Composites Then and Now


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1943 Popular Mechanics Prediction


4/41

Composites Provide HigherStrength and Stiffness

0 200 400 600 800 1000 1200 1400

Specific Modulus, E1/ rho (MSI / pci)

Specific

Ultimate

Tension,

UTS1

(KSI / pci)M60J

M55J

Vectran M

Vectran HS

Zylon AS

DyneemaT-1000

Zylon

M5

M50J

M46JM40J

M35J

M30J

M30ST-800

Boron

M30

T-700G

AS4 T-400H

T300

AS4DSpectra 900

Kevlar 149

Kevlar 49Kevlar 29

S-glass

E-glassQuartz

T-300G

Aluminum

Titanium

Steel

Specific

Fiber Properties Dry

(no resin)

Tension ONLYHM

Fig 2


5/41

Fiberglass Primary Structures -Rotor Blades (1964 flight test)


6/41

MASS Governor Volpe inspectsAutocopter 1966


7/41

767 and Entry Door Spring 1978


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Joe Sutter 1982


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1982 Prediction

Joe Sutter


11/41


12/41


13/41

NormalizedG

rossFailureStress(Ksi)

5 10 15 20 25 30 20 30 40 50 60

XX

X

X

XX XX

XX

End load Nx (Kip/in.) Shear Stiffness Ratio Gt/Nx

20

30

40

50

60

70

10

11-511-5

1B-11J-3

3B-3

27%

Mass Reduction

8%

3J-1

3I-1

3B-3

3B-33J-13I-1

LCPAS 1982 (2220-3)

Rhodes and Williams 1981 (5208)

Aluminum (7150)

Impact damage in. diameter metal impactor

X

LCPAS Compression Panel TestSummary


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Component

Theoretical

Mass

Reduction (%)

Upper Surface

Lower Surface

Spars

Total

(Panels + Spars)

24

49

40

38

LCPAS Wing Sizing Based on TestResults


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500

550

600

650

700

750

800

850

900

1930 1950 1970 1990 2010 2030 2050

Specific Strength

Stress / Density

(Ksi / pci)

Year

DC-3DC-7

B-47

B-52

Comet

737

747

757

767

IACC

Military

Helicopters

Wind Energy

Commercial

Wings

777-wing

Commercial

TailsSpruceGoose

UAVs

7055

2324

2224

7150

7075

2024

Metallics

Composites

Specific Strength Of Wing BendingMaterials


18/41

Setting New Levels of Leadership

Less fuel used

Lower emissions

Quieter for communities,crews, and passengers

Fewer hazardous materials

Less waste in production


19/41

Opening a New Era in Fuel Efficiency

Fuel consumption per trip

F

uelconsumptionperseat

300 SEATS

225 SEATS

250 SEATS

275 SEATS

350 SEATS 400 SEATS

450 SEATS

500 SEATS

550 SEATS

200 SEATS

787

Current

Twins

Current

Quads

20%

Better


20/41

Addressing the Markets Needs(2006-2025)

61%

13%

3%

23%

27,200airplanes

2.6 trill iondelivery dollars*

*In year 2005 dollars

Regional jets

Single-aisle

Twin-aisle747 and larger

45%

41%

4%10%


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23/41

787 Final Assembly FlowEverett, Wash.


24/41

Increased Use of CompositesOver Time

CompositeSteel

Titanium

Aluminum

Miscellaneous

Materials

1%747

3%757/767

11%777 50%

787


25/41

Validation Process Ensures Safety,Reliability

Proven Certification process, validated by

positive service experience

Boeing design objectives typically exceedminimum regulatory requirements

MaterialSpecimens

Elements

Assemblies

Components

Airplanes

Increasing Levels of Complexity

Static TestFatigue Test

Ground & Flight Tests


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Static Test Airframe Moves ToTesting Rig 25 April 2008


27/41

787 Airframe Static Test


28/41

Composites Also On Jet Engines


29/41

Composites at Work with Wind Turbines(Vestas V90)

BOR 90 N t C b Fib Fl i


30/41

BOR 90, Newest Carbon Fiber FlyingMachine, Anacortes, WA 2008

www.GGYC.COM

C it t S ith th M lt


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Composites at Sea with the MalteseFalcon


32/41

Damon Roberts Insensys, Ltd


33/41


34/41

Maltese Falcon Rig Engineering and BuildStructural Overview

Bending moment at deck 17,000,000 Nm

Torque at deck 1,200 kNm

Height 58m

Sail area on each spar 800 sqm

Elliptical spar 1.8m by 1.1m max, tapering to 0.6 by 0.4m

at top and reducing to 1.1m diam at deck

Open slot down compression face


35/41

Maltese Falcon main spar, note slot for furling sails

Masts

M lt F l Ri C d i 4 i


36/41

Maltese Falcon Rig Cured in 4 pieces,secondary bonded together

M lt F l Ri St i


37/41

Maltese Falcon Rig Stepping


38/41

Improvements in Specific Strength


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Specific Strength,

Log (ksi/pci)

Year

Zylon, dry

Vectran, dry

Oil DrillingAL-7050

AL-7150

Wind Energy

Metals

Uni, Rod

Spectra linesGR fiber, dry

Uni, Spring

DC-3

B-52

767 777

AL ladders

Chop Fiber

747

4130

Corvette

787

B-47

DC-7

Autocopter

Nano

Fibers

Comet

Improvements in Specific StrengthDuring the First 100 Years of Composites

1940 1950 1960 1970 1980 1990 2000 2010 2020 2030 2040

AL Ti Steel Wood Plastic Glass CFRP

High Pressure Tanks


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Diverse Modes of Transportation

()()

() ()

()()

+

+

+

+

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+

+

+

() ()+ +

12.0

11.0

10.0

9.0

8.0

7.0

6.0

5.0

4.0

3.0

2.0

1.0

Trave

lTime(Hours)

100 200 300 400 500 600 700 800

Automobile

Commercial AC Using Hub

Commercial AC

Advanced Flying Automobile

Flight Destination (Miles)

Automobile

Commercial w Hub

Commercial AC

AFA Flight Mode

AFA Driving Mode

()()

() ()

()()

+

+

+

+

++

+

+

+

() ()+ +

12.0

11.0

10.0

9.0

8.0

7.0

6.0

5.0

4.0

3.0

2.0

1.0

Trave

lTime(Hours)

100 200 300 400 500 600 700 800

Automobile


Commercial AC



Automobile

Commercial w Hub

Commercial AC

AFA Flight Mode

AFA Driving Mode

()()

() ()

()()

+

+

+

+

++

+

+

+

() ()+ +

12.0

11.0

10.0

9.0

8.0

7.0

6.0

5.0

4.0

3.0

2.0

1.0

Trave

lTime(Hours)

100 200 300 400 500 600 700 800

Automobile


Commercial AC



Automobile

Commercial w Hub

Commercial AC

AFA Flight Mode

AFA Driving Mode

()()

() ()

()()

+

+

+

+

++

+

+

+

() ()+ +

12.0

11.0

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7.0

6.0

5.0

4.0

3.0

2.0

1.0

Trave

lTime(Hours)

100 200 300 400 500 600 700 800

Automobile


Commercial AC



Automobile

Commercial w Hub

Commercial AC

AFA Flight Mode

AFA Driving Mode

On the Land, In the Sky, On the Sea:


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On the Land, In the Sky, On the Sea:The Best Is Yet to Come

Documents

Composites 100 Years