Composites 201 - cdn.ymaws.com...bast fibers such as jute, flax, hemp, ramie, and kenaf; leaf fibers such as banana, sisal, agave, and pineapple; seed fibers such as coir, cotton,

Composites 201

John P. Busel, F.ACI, HoF.ACMA

VP, Composites Growth Initiative

American Composites Manufacturers Association

2

September 21-24, 2020 / www.theCAMX.org

• To build on the information presented in Composites 101 to

provide:

• a greater understanding of FRP composite materials and properties,

and

• options to manufacture composites

• General guidelines in design of FRP composites products

• Help answer the question – why composites.

Objectives of Session

3


Outline

1. Fiber Reinforcements

2. Polymers (matrix)

3. Manufacturing / Product and Process Characteristics

4. Designing with Composites

5. Recycling Composites

4


Composites 101 – An Overview

From the ACMA CCT Program, Composites defined as:

• “A combination of reinforcement fiber in a polymer resin matrix, whereas the reinforcement has an aspect ratio that enables the transfer of loads between fibers, and the fibers are chemically bonded to the resin matrix”.– A combination of fiber in a polymer matrix – A resin matrix reinforced with

a fiber• The reinforcement has an aspect ratio that enables the transfer of loads between fibers

– The fibers are long and narrow, and where they overlap the polymer matrix transfers loads to the adjacent fibers

• The fibers are chemically bonded to the resin matrix – There is adhesion between the fibers and matrix and the fibers do not move within their encapsulation when loaded

5

1. Fiber Reinforcements

6


Constituent Components: FibersTypical Composite Reinforcing Fibers: Glass

• E-Glass (Alumina-calcium-borosilicate):

– General purpose fiber with good strength and high electrical resistivity

– Forms• Single end “direct draw” roving for fabric weaving, stitch-bonding, braiding, pultrusion, filament

winding– From very fine yarn for electrical circuit boards to heavy roving for industrial composites

• Multi-end “assembled” roving for chopped mat

– Nomenclature and composition outlined in ASTM D578

– Typically named after sizing type

– Select Products: • Hybon® 2026 (PPG/NEG), StarRov® (JM), 469L (CPIC), TD44C (Vetrotex)

• ECR-Glass (Calcium aluminosilicate):

– Boron oxide-free version of E-glass which increases acid corrosion resistance

– Produced in same forms as E-glass

– Select Products: • Advantex® (Owens Corning), E6CR™ 396 (Jushi)

7



• A-Glass (Soda lime silicate):

– Lower strength/durability fiber compared to E-glass, only in veil/mat format

– Select Products: • Surmat® 200 veil (Superior Composites Co.)

• H-Glass (Calcium aluminosilicate):

– Higher strength and modulus version of ECR-glass fiber

– Select Products: • Xstrand® H (Owens Corning)

• R-Glass (Calcium aluminosilicate and Basalt):

– Higher strength and modulus than H-glass fiber

– Select Products: • INNOFIBER® Hybon® XM (PPG/NEG)

• C-Glass (Calcium borosilicate):

– Used for highly corrosive acidic environments, usually only in nonwoven veil format

– Select Products: • C64 C-Veil (Owens Corning)

8



• AR-Glass (Alkali zirconium):

– Highly alkali resistant fiber used for cement and concrete reinforcement

– Select Products: • Cem-FIL® (Owens Corning)

• S-Glass (Magnesium aluminosilicate):

– Higher strength and modulus fiber than R-glass, also very good high temperature and corrosion resistance

– Select Products: • S-1 Glass™, S-2 Glass®, & S-3 Glass™ (AGY)

• Quartz (99.99% Pure silica):

– Highly expensive fiber with very low coefficient of thermal expansion (CTE) and superior electromagnetic properties (for radio frequency transparency – radomes)

– Select Products: • Astroquartz® (JPS) , Quartzel® (Saint-Gobain)

9


Constituent Components: Fibers

10



Typical Composite Reinforcing Fibers: PAN Based Carbon– The most widely available and utilized type is produced from a specially formulated

polyacrylonitrile (PAN) precursor fiber

• The PAN carbon fiber is generally classed in 3 different groups

according to modulus– Standard Modulus (SM) / High Strength (HS)

• Most widely used in industrial applications

• Most cost effective

– Intermediate Modulus (IM)• Best blend of strength/modulus,

• Typically used in aerospace/defense applications

– High Modulus (HM)• Highest stiffness, lowest CTE, highest conductivity, & lower strength than SM & IM versions,

highest cost,

• Typically used in space craft/satellites/sporting equipment

11



Classification

Tensile Modulus* Tensile Strength*

Msi GPa ksi MPa

Standard Modulus/High Strength 33-37 230-255 500-725 3,450-5,000

Intermediate Modulus 40-45 275-310 600-925 4,130-6,370

High Modulus 45-87 310-600 275-700 1,890-4,900

*Note: Carbon fiber modulus, strength, and elongation to beak are ideal values produced via

impregnated strand testing and may not translate directly to the corresponding fabric/composite

properties due to fiber misalignment, resin compatibility, and damage during processing

12


Constituent Components: FibersTypical Composite Reinforcing Fibers: PAN Based Carbon

Standard Modulus (SM) / High Strength (HS):

• Small (1K) to Large (60K) tow sizes available, aerospace to industrial grade

• Select Products:

– Toray: T300, T700S & Zoltek (Subsidiary): Panex® 35; Toho-Tenax: HTA40; UTS50, Mitsubishi

Chemical/Grafil: 34-700, TRH50; SGL: C T24, C T50; Hexcel: AS4, AS7; Solvay (Cytec): T-300

– Others: AKSA, Bluestar, Formosa, Hyosung, Dalian Xingke, GanSu HaoShi

Intermediate Modulus (IM):

• Smaller range of tow sizes (6K-24K), recent work on large tow industrial

versions (ORNL)


– Toray: T800H, T1000G; Toho-Tenax: IMS40, IMS65; Mitsubishi Chemical/Grafil: MR40, MR

60H; Hexcel: IM7, IM10; Solvay (Cytec): T-650; Formosa: T-42

High Modulus (HM):

• Small range of tow sizes (3K-12K)


– Toray: M40J, M60J; Toho-Tenax: UMS40, HMA35; Mitsubishi Chemical/Grafil: HR 40, HS 40;

Formosa: TC55

13


Constituent Components: FibersTypical Composite Reinforcing Fibers: Pitch Based Carbon

• Precursor material is by-product of fossil fuel processing: – Coal & Petrol Tar (i.e. Pitch)

• Isotropic: Typically low modulus, used for thermal management applications

• Mesophase Pitch: (made by polymerizing isotropic pitch to a higher molecular weight)

– Highly aligned carbon chains along fiber axis provide extremely high modulus, thermal conductivity and are called “Ultra High Modulus” (UHM) carbon or graphite fiber

– 1K-16K tow sizes typically available

– There has been work on lower cost precursor (ref. CompositesWorld)

– Applications: aerospace, civil engineering (concrete strengthening), sports – golf shafts

• Select Products:– Mitsubishi Chemical: DIALEAD® K63712, K13C2U

– Nippon Graphite Fiber: GRANOC YSH-50A-10S, YS-80A-60S

Classification

Tensile Modulus* Tensile Strength*

Msi GPa ksi MPa

Ultra High Modulus 75-136 520-935 375-550 2,600-3,800

*Note: Carbon fiber modulus, strength, and elongation to beak are ideal values produced via impregnated strand testing and may not translate

directly to the corresponding fabric/composite properties due to fiber misalignment, resin compatibility, and damage during processing

14



Typical Composite Reinforcing Fibers: Polymer Based

• Para-Aramid:

– Low density and high strength with high impact and fatigue resistance

– Fiber exhibits a “soft” failure mode in that it doesn’t shatter upon impact or flexing

– Has UV and moisture absorption issues

– For composites, use the “high modulus” versions: K49, K149, & T2200, low modulus for

ballistics (K29)

– Select Products:

• Kevlar® (Dupont) & Twaron® (Teijin)

15


Constituent Components: FibersTypical Composite Reinforcing Fibers: Comparison

Tensile

Strength

Tensile

ModulusElongation Density Cost

ksi Msi % lb/in3

E-Glass 290 to 360 10 to 10.5 3 to 5 0.092 to 0.094 $

E-CR Glass 320 to 375 11.75 3 to 5 0.095 $

H-Glass 350 to 420 13.00 3 to 5 0.094 $$

R-Glass 440 to 493 13.00 5.35 0.092 $$$

S-Glass 495 to 555 13.25 5.50 0.089 $$$$

Basalt (R-Gl.) 392 to 464 12.34 to 13.79 3 to 5 0.096 $$$$

SM Carbon 500-725 34 to 37 1.5 to 2.0 0.065 $$$$$

IM Carbon 600 to 925 40 to 45 1.5 to 2.2 0.065 $$$$$$

HM Carbon 275 to 700 45 to 87 ~1.0 0.063 to 0.069 $$$$$$$

UHM Carbon 380 to 550 114 to 135 >1.0 0.070 to 0.078 $$$$$$$$

Aramid (K49) 525 16.30 2.4 0.052 $$$$$

Aramid (K149) 501 26.00 1.9 0.053 $$$$$$

FIBER PROPERTIES (IMPREGNATED STRAND)

Ara

mid

Fiber

Type

Gla

ss

Carb

on

16


Constituent Components: FibersTypical Composite Reinforcing Fibers: Polymer Based

• Polypropylene: Innegra™ (Innegra Technologies)

– Extremely (< 1.0 g/cc) low density polyolefin fiber with very good dynamic response characteristics

– Fairly low mechanical properties, but a cost-effective alternative to para-aramid / UHMWPE / PBO/LCP fibers with

better matrix resin bonding properties

– Works well as a hybrid with more brittle fiber (i.e. carbon) for increased ductility and impact resistance

• Ultra High Molecular Weight Polyethylene - UHMWPE: Spectra® (Honeywell) & Dyneema® (DSM)

– Very low-density polyolefin fiber made of extremely long polymer chains of polyethylene

– High resistance to chemicals, water & ultraviolet light, 40% stronger than aramid fiber

– Capable of withstanding high-load and strain-rates

– Need special fiber surface modifications to properly bond to composite matrix resins, can have creep issues

• Polybenzoxazole - PBO: Zylon® (Toyobo)

– Comparable to slightly higher tensile properties compared to UHMPE fibers, but with higher heat resistance

– The fiber is almost twice as strong as aramid fibers, about 10 times stronger than steel

– Also needs surface treatments for proper use with composite resins

• Liquid Crystal Polymer - LCP: Vectran™ (Kuraray)

– Excellent creep and abrasion resistance, minimal moisture absorption, chemical resistance, Low CTE, high dielectric

strength, & high impact strength

– Same bonding issues as with UHMWPE and PBO fibers.

– Outstanding strength at extreme temperatures, resistance to virtually all chemicals, weathering, radiation and burning

– Pound for pound, Vectran™ is 5x stronger than steel, 10x stronger than aluminum

17


Constituent Components: FibersTypical Composite Reinforcing Fibers: Other/Special

• Ceramic:

– For high temperature applications up to 2372°F (1300°C)

– Used in ceramic matrix and metal matrix composites

– SiC (Silicon Carbide):

• High strength properties up to 2192°F (1200°C), wettability for metals, low electrical

conductivity, high heat resistance, and corrosion resistance/chemical stability

• Select Products: SCS-6 (Specialty Materials, Inc.), Tyranno Fiber® (UBE Industries)

– Oxide/Alumina:

• High chemical stability, high melting point, high modulus, and good strength at high

temperature

• Select Products: Nextel™312, Nextel™440 (3M)

• Boron:

– Elemental boron is deposited on a fine tungsten wire substrate and produced in

diameters of 4mil up to 11mil.

– Known for high compression properties, but low conformability

• Select Products: Boron fiber (Specialty Materials, Inc.)

Typical SiC / Alumina Fiber Application

SEM Photo of Boron Fiber

18



Natural: using these fibers revolve around environmental sustainability

• Typical Example Types:

✓ bast fibers such as jute, flax, hemp, ramie, and kenaf;

✓ leaf fibers such as banana, sisal, agave, and pineapple;

✓ seed fibers such as coir, cotton, and kapok;

✓ core fibers such as kenaf, hemp, and jute;

✓ grass and reed fibers such as wheat, corn, rice, and bamboo

• Advantages:

– Low density, are biodegradable, are derived from renewable resources, have a small carbon footprint, provide good thermal

and acoustical insulation, good vibration damping, moderate mechanical properties and high specific properties

• Challenges:

– Still have matrix-fiber interface issues – hydrophilic nature makes them incompatible with existing hydrophobic resin systems

used in the industry

– Very low load transfer efficiency

– There are few in the composites industry with enough experience to work with them confidently

– Mostly derived from plants grown in developing countries such as Bangladesh, India, Sri Lanka, also China

• Select Products: Most natural fiber reinforcements are used in nonwoven form

– Increasing use in automotive interior panels

– Flax: Biotex (Composites Evolution)

– Cellulose: BioMid® (GS Consulting)

19



Graphene: • A single, 2D layer of carbon atoms, tightly packed in a hexagonal lattice structure

• Graphite is made up of millions of layers of Graphene– 1 mm of graphite is ~3 million of layers of Graphene thick

– Graphite is mixed with clay to make pencil “lead”

• Properties– It is the thinnest, strongest material yet discovered and the most efficient conductor of both heat and electricity currently

available

– Size: Single-Wall Carbon Nanotubes (SWCNT) = ~1-2 nm, DNA = 2.5 nm

• Perspective: COVID-19 Virus Diameter is 350-400 x The Thickness of Graphene!

– Strength: 300 times the tensile strength of steel

– Performance: 20 times the thermal conductivity of copper, 5-6 times of diamond

– Electrical: Can be a Semiconductor, a Superconductor or a perfect Insulator depending on how it is used

– Appearance: Nearly transparent, at one layer, Graphene absorbs ~1.7% of light

• How is Graphene made?– Mechanical Exfoliation

– Chemical Vapor deposition (CVD)

• Where has Graphene been used– Clothing, golf balls, ink, tires, concrete, asphalt, fire retardant paint, coatings

– Automotive – engine compartment, sound-attenuating foam for 2019 F-150 and F-250 Pickup, Lincoln Navigator and Mustang

20

2. Polymers (Matrix)

21


Constituent Components: MatrixTypical Composite Thermoset Matrices

– Unsaturated Polyester (UPR)

• Accounts for approximately 75% of matrix resins used for composites molding

• Comprises isophthalic, orthophthalic, DCPD, and terephthalic based systems

• Polymer comes mixed with a reactive diluent (typically styrene)

– Vinyl Ester

• Formulated by reacting an epoxy (Bisphenol-A or Novolac) backbone with methacrylic acid, forming a polymer that has

characteristics of both UPR and epoxy

• Superior corrosion resistance, low water permeability, and good fatigue resistance

– Epoxy

• Most widely used matrix resin in high performance applications

• Superior mechanical properties, resistance to corrosive environments, superior electrical properties, and elevated

temperature performance

– Urethane/Urea

• Highly reactive 2-part matrix resin producing high flexibility and toughness

• Moisture sensitive cure and components can be a health hazard (isocyanates)

– Phenolic

• Low structural properties, but very good fire resistance

• Condensation reaction (produces water) which can lead to porosity in the laminate when manufactured

22


Constituent Components: Matrix

Typical Composite Thermoset Matrices

• High Temperature– BMI & Polyimide:

• High temperature resistance (service temp up to

260°C), chemical and radiation stability

– Cyanate Ester: • High Tg (300°C), low outgassing, and low dielectric

constant and loss

– Benzoxazine: • Excellent stiffness and high-temperature

performance, low resin shrinkage for improved

dimensional stability

23


Constituent Components: Matrix

Typical Composite Thermoset Matrices

• Hybrids– Urethane Ester:

• Excellent toughness, adhesion, water resistance, and speed of cure

• Select Products: – Xycon® 047-8023 (Polynt)

– Urethane Acrylate: • Similar in properties to the urethane ester, and has a Tg around 280°C

• Select Products: – Crestapol® 1250LV (Scott Bader)

– Core Shell Rubber-Modified Vinyl Ester: • Nano-particle enhance technology that significantly improves the impact and energy

absorbing properties of a polymer matrix

• Select Products: – 781-6010 (Polynt)

24


Constituent Components: MatrixTypical Composite Thermoplastic Matrices

• Commodity– Polypropylene (PP): Low cost polymer, low melting point, excellent moisture

resistance

– Polyester (PET) : Low cost polymer, high chemical resistance, low moisture regain

– Polyamide 6 (Nylon 6): Good price/performance ratio, good chemical resistance, high strength

– Polyamide 12 (Nylon 12): Lower moisture regain and lower melting point than Nylon 6, good resistance to shock and chemicals

• Engineered/High Temperature– Polyetherimide - PEI: High thermal stability, low flame and smoke, similar to PEEK

but lower temperature resistance and impact strength

– Polyphenylene sulfide - PPS: Chemical resistance, flame retardancy, dimensional stability, low moisture absorption

– Polyetheretherketone - PEEK: Thermal stability, abrasion resistance, superior chemical resistance, flame retardancy, high stiffness and low density

– Polyaryletherketone - PAEK: Highly fire-resistant, has good chemical resistance, and can be used for high temperature applications

25

3. Manufacturing / Process and

Product Characteristics

26


The World of Manufacturing

• Teamwork is important

– Design Engineer

– Stress Engineer

– Manufacturing Engineer

– Materials Engineer

– Tool Designer/Tool Engineer

– Technicians

– Inspection/Quality

27


Process Selection Considerations

28

• Surface complexity expense of the tool

• Performance complexity of laminate fiber architecture

• Surface appearance secondary operations needed

• Size of the part hand vs machine

• Production rate hand vs machine

• Total production volume hand vs machine

• Economic target (limit) hand vs machine

– Part cost

• materials, tooling, equipment, labor)


Categories of Manufacturing Processes

• Open Molding

– One side is a tool surface, opposite side there is no tool surface

• Closed Molding

– There is a tool surface on both sides

• Types of Manufacturing Processes

– Common or Basic

– Advanced

29


Typical Open Molding Processes

• Casting (Cast Polymer Molding)

• Centrifugal Casting

• Filament Winding– Wet winding

– Prepreg winding

• Hand Lay-up– Wet Lay-up vacuum bagging

– Prepreg Lay-up vacuum bagging (autoclave molding)

• Spray-up

30


Typical Closed Molding Processes

• Compression Molding– Wet Compression Molding (WCM) (also known as liquid molding or

cold molding)

– Sheet Molding Compound (SMC)

– Bulk Molding Compound (BMC)

– Dynamic Fluid Compression Molding

• Continuous Lamination

• Cured In-Place Pipe (CIPP)

• Extrusion

31


Typical Closed Molding Processes

• Injection Molding– Bulk Molding Compound (BMC)

– Hybrid injection-molding/thermoforming

• Pultrusion

• Reinforced Reaction Injection Molding (RRIM)– RIM Overmolding

• Resin Transfer Molding (RTM)– Light RTM

• Vacuum Assisted RTM (VA-RTM)– Resin Infusion

– Vacuum Infusion Processing (VIP)

– High Pressure – RTM (HP-RTM)

32


Hand Lay-Up

33

Just about anything, large or small


Vacuum Vacuum

Wet Lay-up Vacuum Bagging

3434

Just about anything, large or small


Spray-Up Process

35

Boats, tubs, showers, sinks, panels


PROCESS Characteristics

Hand Lay-up / Spray-up

• MAX SIZE: Unlimited

• PART GEOMETRY: Simple - Complex

• PRODUCTION VOLUME: Low - Med

• CYCLE TIME: Slow

• SURFACE FINISH: Good - Excellent

• TOOLING COST: Low

• EQUIPMENT COST: Low

36


PRODUCT Characteristics

Hand Lay-up / Spray-up

• Small to large parts achievable

• Cost effective solution

• Prototype to production parts

• Any shape, size, surface texture possible

• Laminates, sandwich panel construction

• Complicated lay-up of lamina possible

• Inexpensive to expensive materials could be used

• Can be automated with spray-up

• Highly operator dependent – potential for wide variations in quality

37


Filament Winding

Resin

Utility poles, columns, pipe, missile casing, tanks, stack liners

38



Filament Winding

• MAX SIZE: <65’ Diameter

• PART GEOMETRY: Simple


• CYCLE TIME: Low - Med

• SURFACE FINISH: Inside - Good/Excellent, Outside – Fair**

• TOOLING COST: Med - High

• EQUIPMENT COST: Med - High

**depends on material (wet vs prepreg)

39



Filament Winding

• Body of revolution

• Controlled strength

• Directional strength

• Computer controlled fiber placement

• Low labor

• Products can be made in the factory or out in the field

• Emission controls required (except pre-preg)

40


Centrifugal Casting

• Centrifugal Casting is used for making cylindrical, hollow shapes such as tanks, pipes and poles.

• Chopped strand mat is placed into a hollow, cylindrical mold, or continuous roving is chopped and directed onto the inside walls of the mold.

• Resin is applied to the inside of the rotating mold

Source: CompositesLab.org

41



Centrifugal Casting

• MAX SIZE: <15’ Diameter

• PART GEOMETRY: Simple

• PRODUCTION VOLUME: Med

• CYCLE TIME: Low - Med

• SURFACE FINISH: Good

• TOOLING COST: Med

• EQUIPMENT COST: Med

42



Centrifugal Casting

• Body of revolution

• Outside surface is finished (tool side)

• Limited part size (mold and machine)

43


SMC

Compression Molding

44



Compression Molding

• MAX SIZE: Limited by Press Machine


• PRODUCTION VOLUME: High

• CYCLE TIME: Fast


• TOOLING COST: High

• EQUIPMENT COST: High

45



Compression Molding

• High Volume Output

• Inside & Outside has finished “tool” surface

• Low per part cost in high volume manufacturing

• Low finishing cost

• Close part tolerances are achievable

• Molded-in texture and color possible

• Low scrap materials – supports sustainability

46


Compression Molding

• Alternative Molding Materials:

– Sheet Molding Compound (SMC)

– Bulk Molding Compound (BMC)

– Wet layup and preform system

– Reinforced thermoplastic sheet goods

47


SMC

• PROCESS Characteristics – High volume productions

– High equipment and mold costs

– Low labor costs

– Engineered material systems

– Process reproducible

• Advantages– Directly formed to net shape

– Integral ribs and bosses

– Variable wall thickness possible

48

Source: IDI Composites International

SMC - mixture of polymer resin, inert

fillers, fiber reinforcement, catalysts,

pigments and stabilizers, release agents,

and thickeners and possesses strong

dielectric properties


BMC

• PROCESS Characteristics– High equipment and mold cost

– Low labor

– High material efficiency

– Highly reproducible

• Advantages– Can mold highly complex shapes

– Can be used in both compression and injection molding

– Low cost alternative

49

BMC - Is a thermoset resin blend of

various inert fillers, fiber reinforcement,

catalysts, stabilizers, and pigments that

form a viscous, 'puttylike' injection

molding compound. It is often highly filled

and reinforced with short fibers.


Pultrusion

Resin

Heated DieCured

Profile

Bridge decks, rebar, structural profiles, sheet piling, dowel bars,

utility poles & cross arms, grating, cable trays, marine pier decks

50



Pultrusion

• MAX SIZE: Length: Unlimited, Width: Tool Dependent


• PRODUCTION VOLUME: Med - High

• CYCLE TIME: Med


• TOOLING COST: Med - High

• EQUIPMENT COST: Med - High

51



Pultrusion

• Constant cross section shapes

• Continuous lengths

• Highly oriented strengths (longitudinal direction)

• Complex profiles possible

• Hybrid reinforcements can be used

• **shapes can be curved

52


Resin Transfer Molding

Resin Injection Unit

Vent Vent

53



• LRTM: “Light Resin Transfer Molding”

– Low pressure thermoset resin injection w/ reinforcement

loading between matched low cost tooling

• RTM: “Resin Transfer Molding”

– Higher pressure thermoset resin injection w/

reinforcement loading between matched tooling

54




• MAX SIZE: 6’ x 6’

• PART GEOMETRY: Complex

• PRODUCTION VOLUME: Med

• CYCLE TIME: Med


• TOOLING COST: Med

• EQUIPMENT COST: Med

55




• Two controlled tool surfaces

• Molded in finishes

• Molded in stiffeners and connection points

• Large part capable, depends on tool size

56


Vacuum Vacuum

Vacuum Infusion Processing

VIP

Resin

Boats, marine piling, bridge decks,

architectural products,

➢ VARTM

➢ Resin Infusion

➢ SCRIMP™

57



VIP (VARTM)

• MAX SIZE: Unlimited



• CYCLE TIME: Slow-Fast (size dependent)


• TOOLING COST: Low

• EQUIPMENT COST: Low

58



VIP (VARTM)

• No voids

• High fiber volume (65%)

• High strength applications

• Large part size– Flat

– Curve or rounded

– Long (limited by shipping)

• Fabrication possible in the field, although controlled factory conditions are preferred

59


Advanced Manufacturing Processes

• Autoclave Molding– Prepreg

• Co-Curing

• Automated Tape Placement (ATP)

• Automated Fiber Placement (AFP)

• Out of Autoclave Processing– Vacuum Bag Molding

– Reusable Bag Molding (RSBM)

• Additive Manufacturing (AM)

60


Autoclave Molding

Pre-Preg Vacuum Bagging

61

Vacuum Vacuum

61


Automated Fiber Placement

Source: Electroimpact.com

62


Automated Tape Placement

Source: Sciencedirect.com

Source: CompositesWorld.com

63


Additive Manufacturing

• Types of Additive Manufacturing Processes– 3-D Printing

• Reactive Additive Manufacturing (RAM) new

– Digital Light Processing (DLP)

– Fused Deposition Modeling (FDM)

– Fused Filament Fabrication (FFF)

– Selective Laser Sintering (SLS)

– Stereolithography (SLA)

• BAAM – Big Area Additive Manufacturing

64




• MAX SIZE: Small - Large



• CYCLE TIME: Slow-Med (size dependent)


• TOOLING COST: High

• EQUIPMENT COST: High

65




• Prototype to full production

• Long time to qualify materials

• Can expect no voids in laminate – process dependent

• High fiber volume (+65%)

• High Strength Applications

• Large part size– Flat

– Curved or rounded

– Long (limited by shipping)

– Complex contour

66

4. Designing with Composites

67


Thinking Composites

• Composites are simply another material system.

• They are not the only solution for all product applications.

• Each individual material has a unique set of attributes that

determine whether that material is suitable.

• A composite design should not imitate both form and

function of an existing design in another material if

composites are to offer value.

6868


Composites Features

❖ High Strength

❖ Corrosion resistance

❖ Light weight

❖ Electrical properties

❖ Thermal properties

❖ Non-magnetic

❖ Dimensional stability

❖ Part consolidation

❖ Design flexibility

❖ Unique shapes

❖ Damage tolerance

❖ Radar transparency

❖ Tailored surface

❖ Long-term durability

❖ FDA compliant

69


Part Design with Composites:

Short Fiber Composites

• Why are short fiber composites needed?

– Low cost/high volume production• Both for thermoplastic (milled fiber injection molding) & thermoset (SMC)

– Ease of fabricating complex part geometries• Continuous fibers can be difficult to conform and stretch and can become

distorted and damaged

– Isotropic behavior• Randomly oriented short fiber composites give isotropic behavior response,

which makes them easier to analyze

70



Short Fiber Composite Material Forms

• Milled Fiber: – 3 to 60mil long fibers– Reinforces body fillers, casting material and injection molded thermoplastics to increase

strength/stiffness and dimensional stability by reducing shrinkage– Increase electrical/thermal properties (milled carbon fiber)

• LFRT: – “Long Fiber Reinforced Thermoplastic” – with fibers up to 0.5in in length– Mid-range material with properties between milled fiber and chopped fiber

thermoplastic composites• Longer fibers allow for higher fiber content composites, driving up mechanical performance

• Chopped Fiber: – Composites typically having 2-4in long fibers– Majority of consumer good “fiberglass” (bathtubs, body panels, etc.)

• Most LRTM and RTM process applications w/permeable core material

71



Short Fiber Composites

72



Continuous Fiber Composites Material Forms• Woven fabrics

Plain Weave

Basket Weave

4-Harness Satin

Weave (Crowfoot)

73



Continuous Fiber Composites Material Forms• Woven fabrics

8-Harness Satin

WeaveLeno Weave2x2 Twill Weave

74



Continuous Fiber Composites Material Forms

• Braids

– Similar to wovens, but can be used to make cylindrical and

other cross sectional shape preforms

– Can be slit to create broadgood fabrics

0/60/-60 Braided

Broadgood Braided Beam75




• NCF – Non-Crimp Fabrics

– Up to 30% higher in-plane strength compared to equivalent areal

weight woven reinforcements

• No fiber crimp = No stress concentrations, higher fiber property translation

• Lower amount of resin required for complete saturation

• Greater stability, less skewing during processing

76




• NCF – Non-Crimp Fabrics– Typically available constructions

– Up to 4 plies/layers per one-pass fabric

– Bias angle vary from 300 to 900

– ±450, ±600, & 900 are most common

– Standard constructions

• Unidirectional (00 & 900),

• Biaxial (00/900 & +450/-450),

• Triaxial (00/+450/-450 & +450/900/-450), &

• Quadriaxial (00/+450/900/-450)

77



Continuous Fiber Composites Material Forms• Other Forms

– 3D Wovens

• Non-Crimp Woven with Z-axis fiber

• 3D preforms

– Prepreg

• Unidirectional – Narrow tapes to wide widths

• Fabric – Wovens, braids, NCF

Carbon Fiber Uni Prepreg Tape

3D Woven Preform

Non-Crimp Fabric w/Z-Axis Fiber

78


FRP Composites

Thermoset Composites

• Typical Thermoset Composites– E-Glass/UPR:

• Most common for industrial composites

– ECR-Glass/VE: • Used for highly corrosive applications (rebar, scrubbers, jet bubble reactors, etc.)

– SM Carbon/Epoxy: • The standard for high performance composites in aerospace, sporting goods, and

COPV’s

– SM Carbon/VE: • Gaining use in marine and industrial composites. Needs to be evaluated per

application

79


FRP Composites

Thermoset Composites• Typical Thermoset Composites

Tensile

Strength

Tensile

ModulusElongation Density

ksi Msi % lb/ft3

E-Glass/VE 185 5.87 3.15 121

E-CR Glass/VE 197 6.67 2.95 123

H-Glass/VE 218 7.35 2.97 123

R-Glass/VE 264 7.35 3.59 120

S-Glass/VE 297 7.49 3.97 117

Basalt/VE 242 7.39 3.27 124

SM Carbon/VE 340 18.90 1.80 95

IM Carbon/VE 423 23.30 1.82 95

K49/VE 295 9.17 3.22 82

K149/VE 280 14.50 1.93 83

Carb

on

Ara

mid

COMPOSITE PROPERTIES (UNIDIRECTIONAL) Vf = 55%

Composite

Type

Gla

ss

Tensile

Strength

Tensile

ModulusElongation Density

ksi Msi % lb/ft3

E-Glass/VE 69 4.18 1.65 121

E-CR Glass/VE 76 4.63 1.64 122

H-Glass/VE 83 5.04 1.65 122

R-Glass/VE 83 5.07 1.64 120

S-Glass/VE 86 5.21 1.65 118

Basalt/VE 83 5.04 1.65 123

SM Carbon/VE 219 13.37 1.64 103

IM Carbon/VE 268 16.36 1.64 103

K49/VE 117 7.13 1.64 93

K149/VE 180 10.98 1.64 93Ara

mid

COMPOSITE PROPERTIES (BIAXIAL 60%/40%) Vf = 55%

Composite

Type

Gla

ss

Carb

on

80


Polymer Matrix Composites (PMC):

Thermoplastic Composites

• Typical Thermoplastic Composites

– E-Glass/PP:

• Commodity grade composite for industrial uses

• Commingled continuous fiber & LFRT

– E-Glass/Nylon:

• Higher performance and cost over E-glass/PP

– SM Carbon/PPS (Polyphenylene sulfide):

• High temperature & mechanical performance

– SM Carbon/PEEK:

• Similar use to SM carbon/PPS, can be comparatively

difficult to process

Carbon / PEEK Aircraft Door Fitting

Jushi Compofil™ E-Glass/PP Commingled Fiber

Woven Fabric

81


Property Comparison of FRP

with Legacy Materials: Advantages

• High Specific Strength & Stiffness

• Inherently Corrosion Resistant

• High Durability

• Flexibility: Design & Production

82


Property Comparison of FRP

with Legacy Materials: Disadvantages

• Lower Direct Stiffness– Steel: 30Msi,

– Aluminum: 20Msi

• Flammability / Temperature

• Moisture

• Cost

• Availability

• Acceptance– Learning Curve

83

5. Recycling Composites

84


Recycling Composites• Can Composites be recycled – Yes!

– Composites are strong, durable, and non-homogenous which make them inherently difficult

to recycle

• Opportunities to recycle:

– In-process manufacturing scrap

– End-of-Life service scrap

• Thermoset Composite materials can be recycled or recovered through many processes

– Mechanical grinding,

– Thermal (pyrolysis, fluidized bed),

– Thermo-chemical (solvolysis),

– Electro-mechanical (high voltage pulse fragmentation)

– Or combinations of these

– There are advantages and disadvantages of each

• Thermoplastic Composite materials can be shredded and recycled by melting, but the supply

chain is limited

85


Recycling Composites• Business Proposition

– Glass fiber composites is all about volume

– Carbon fiber composites is all about value

– Growing supply chain of companies that recycle composites

– Markets exploring composites recycling include wind energy (blades), aerospace(manufacturing scrap and plane components), automotive (car components), marine (boats)

• Cement co-processing, also known as the cement kiln route, is a main technology for recycling composite scrap

• Different global regions are more advanced in technology and applying recycled materials than others, but there is general global industry collaboration

• What is needed:

– Establishment of a recycling supply chain to collect, sort, process and deliver composites scrap support the cement kiln, grinding, pyrolysis, and other routes.

– Market pull for recycled composite products

– Standardization of recycling composites process, selection, and use

– End-user qualification of recycled composite parts

– The Composites Industry needs to think and design for sustainability!

86


Acknowledgements

• Special thanks to the following people who contributed information to this presentation:

• Trevor Gundberg, P.E., Vectorply Corporation

• Andrew Pokelwaldt, CCT-I, ACMA

• Steve Rogers, EmergenTek, LLC

• Dan Coughlin, ACMA

87


Thank you!

John P. Busel, F.ACI, HoF.ACMA

VP, Composites Growth Initiative

American Composites Manufacturers Association

[email protected]

(914) 961-8007

88

Documents

Composites 201 - cdn.ymaws.com...bast fibers such as jute, flax, hemp, ramie, and kenaf; leaf fibers such as banana, sisal, agave, and pineapple; seed fibers such as coir, cotton,