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.