ME 7502 Lecture 1 - Dr. Brian Sullivanvucoe.drbriansullivan.com/wp-content/.../Lecture-1... · ME 7502 Introduction - Dr. Brian J. Sullivan 1 • Definitions • Particulate Composites

ME 7502 Introduction - Dr. Brian J. Sullivan 1

• Definitions • Particulate Composites • Laminated/Lamellar Composites • Fiber Composites • Fiber Composite Manufacturing Processes • Applications of Composite Material and

Structures • Composite Material/Structural Design Process • Matrix Algebra • MathCAD

ME 7502 Lecture 1 – Introduction to Composite Materials and Composite Structures

2

DEFINITIONS COMPOSITE MATERIAL: A MATERIAL SYSTEM COMPOSED OF TWO OR MORE DIFFERENT, INSOLUBLE MATERIAL PHASES

MATRIX PHASE: A MATERIAL PHASE CONTINUOUSLY CONNECTED TO ITSELF

INCLUSION OR REINFORCEMENT PHASE: A MATERIAL PHASE COMPLETELY SURROUNDED BY MATRIX WHICH USUALLY APPEARS AS MANY DISCRETE UNCONNECTED GEOMETRICAL PARTS

PHASE VOLUME FRACTION vp = vol. of phase/total vol.

PHASE WEIGHT FRACTION wp = wt. of phase/total wt.

wm = matrix wt. fract. vm = matrix vol. fract.

w/o = weight percent v/o = volume percent

wp = particle wt. fract. vp = particle vol. fract.

wf = fiber wt. fract. vf = fiber vol. fract.

wi= inclusion wt. fract. vi = inclusion vol. fract.

WEIGHT VOLUME

ME 7502 Introduction - Dr. Brian J. Sullivan

3

UNIDIRECTIONAL FIBER

PARTICULATE

LAMINAR/LAMINATED FLAKE FILLED

2-D WOVEN 3-D WOVEN BRAIDED

SHORT FIBER

TYPES OF COMPOSITES


4

PARTICULATE COMPOSITES INCLUSIONS HAVE 3 DIMENSIONS ON SAME ORDER OF MAGNITUDE

• DISPERSION-HARDENED METALS • METAL (Al, Steel)/POLYMER - INCREASE ELECTRIC/THERMAL CONDUCTIVITIES • METAL/CARBON - RESISTORS • CERMETS (CERAMIC INCLUSION/METAL MATRIX) - UP TO 30% VM

Al2O3/Cr ---------- LOW MOLTEN-METAL-WETTING, LOW FRICTION, MgO/Cr ---------- RESIST THERMAL SHOCK, EROSION, ABRASION, FLAME, HIGH THERMAL CONDUCTIVITY

W Carbide/Co, Cr Carbide/Co, Ti Carbide/Co ---------- GOOD RESISTANCE TO ABRASION, IMPACT, USED IN MOLTEN METAL FLOW GUIDES, WIRE DIES, PRECISION ROLLS, GAGES, VALVE PARTS, CUTTING TOOLS • FILLER/POLYMER

Ca Carbonate, Clay LOW COST, HIGHER STIFFNESS Glass µ spheres MOLDED ITEMS, AUTO PARTS

Carbon/Rubber


5

LAMINATED/LAMELLAR COMPOSITES REINFORCING PHASE HAS ONE DIMENSION MUCH SMALLER THAN THE OTHER TWO

LAMELLAR FLAKE / MATRIX GLASS POLYMER (EPOXY, PHENOLIC, POLYESTER) METAL METAL (Al, Iron) AlB2 GRAPHITE HIGHER E, K, Strength, etc., THAN MATRIX, GREATER PACKING DENSITY THAN PARTIC., LOWER COST THAN FIBERS

AlB2 flake

LAMINATED -METAL CLAD/COATED METALS Al/U Ti/Steel Cu/W Al/Be Ni, Cu, Al, Au, Ag, Sn, Pb/Mo (Electrical, Chemical, Thermal Applications) -CERAMIC/METALS, CERAMIC/CERAMIC (CORROSION, HEAT-RESISTANT) -PAPER/POLYMER -LAMINATED UNIDIREC. & WOVEN Gr/Ep


6

FIBER COMPOSITES

FIBER GLASS GRAPHITE/CARBON BORON SiC

OXIDE

LAMINATE UNIDIRECTIONAL OR WOVEN, STACKED MULTIDIRECTIONALLY

SHORT FIBER “CHOPPED” FIBER

1/4” - 2”

CONTINUOUS FIBER FILAMENT - SINGLE STRAND ROVING - 10-200 “ENDS” TOW - 1,000-10,000 “ENDS”, NOT TWISTED YARN - 1,000-10,000 “ENDS”, TWISTED

+MATRIX


7

SHORT FIBER COMPOSITES SHORT (25 mm) FIBERS + FILLER + RESIN

(a) SMC-R30 (b) SMC-C40 R30 (c) XMC

SMC-R SHEET MOULDING SMC-CR XMC COMPOUND FIBERS 25-30%W SMC-R + SMC-CR, BUT RESIN 30%W CONTINUOUS FIBERS CONTINUOUS FILLER 40-45%W FIBERS @ ±5-7°

SHEET FORM

HMC - STRUCTURAL GRADE SMC (60-65%W FIBERS) BMC - BULK MOLDING COMPOUND - SMC IN BULK FORM


8

HIGH-PERFORMANCE FIBER COMPOSITES MULTIDIRECTIONAL, CONTINUOUS FIBER COMPOSITE

FIBER PHASE GLASS

GRAPHITE (CARBON)

BORON

ARAMID (KEVLAR)

CERAMICS

- SiC

- OXIDE

MATRIX PHASE POLYMERS

CERAMICS

METALS

TOW (1K-10K ENDS)

TAPE

FILAMENT WINDING

ROVING (~100 ENDS)

YARN (TW 1K-10K ENDS)

WOVEN FABRIC

BRAIDED PREFORM

3-D WOVEN PREFORM


9

WOVEN GLASS ROVING

BORON TAPE

BRAIDED PREFORM KEVLAR 49 TOW


10

TAPE OR THERMOSET

FABRIC RESIN + “PREPREG”

PLY STACKING CERAMIC MATRIX TAPE OR FABRIC +

FIBER COMPOSITE LAMINATE

FILAMENT WINDING TOW + RESIN

-HIGH STRENGTH -LOW WEIGHT

-HIGH STIFFNESS -TAILORABILITY OF THERMO-MECHANICAL PROPERTIES

-GOOD FATIGUE CHARACTERISTICS

-CMCs : EXCELLENT HIGH TEMPERATURE APPLICATIONS

(CMC)

(PMC)

(PMC)


11

FIBER COMPOSITE LAMINATE - INDIVIDUAL PLY MAY BE UNIDIRECTIONAL OR WOVEN

STACKING SEQUENCE/PLY LAY-UP SYMMETRY [0/+45/-45/-45/+45/0] = [0/+45/-45]S

REPEATED SEQUENCE [0/90/0/90] = [0/90]2 [0/0/+45/-45] = [02/+45/-45] COMMON LAY-UPS : [0i/±45j/90k]s ; [0i/±θj] [0/+45/-45/-45/+45/0] [0/±45]S OR [02/±45]S - BENDING, TORSION [0 /±45/90]S - [0/±60]S - QUASI-ISOTROPIC


12

FIBER COMPOSITE MANUFACTURE

THERMOSET MATRIX, CONTINUOUS FILAMENTS

Manual Lay-up... •-APPLY GEL COAT, FIBERS, RESIN •-POSITION PREPREG •-APPLY FIBERS / WOVEN FABRIC, INJECT RESIN

...+cure •-FREE CURE (R.T. THERMOSETS) •-VACUUM BAG OR PRESSURE BAG, THEN AUTOCLAVE (250° - 350°F, 50 - 100 psi) •-COLD PRESS MOLDING (RT) OR •-MATCHED METAL DIE COMPRESSION MOLDING

(250° - 350°F, 200 - 1500 psi)


13

Filament Winding Sheet Continuous Lamination Pultrusion


14

THERMOSET MATRIX, SHORT FIBERS Manual Lay-up of Prepreg, Cure Sheet Continuous Laminating Spray-Up


15

THERMOPLASTIC MATRIX Pultrusion (Continuous Filaments) Injection Molding (Short Fibers) Extrusion Hot Forming (Preformed Sheets)

METAL MATRIX Diffusion Welding -Press/Sinter Matrix Powder, Bare/Coated Fibers -Press Coated Fibers -Press Fibers between Foil (+Powder) Liquid Wetting -Liquid Metal Infiltration of Fibers -Heat Powder & Fibers above Matrix Solidus Deposition -Matrix electrodeposition, Vacuum deposition, or Plasma Spray onto Fibers, Press


16

RESIN MATRIX PROCESSES Hand Layup Vacuum Bag Layup


17

Pressure Bag Molding Auto-clave Molding


RESIN MATRIX PROCESSES (cont’d)

• Out-of-Autoclave Composite Manufacturing offers – Reduced recurring costs – Reduced cycle times for primary structures – Potential improvements in quality by reducing

pressure and resin flow – Utilizes resins specifically engineered for lower

pressure, lower temperature cures – Can enable manufacture of some very large

primary composite structures – Co-cures of separately fabricated parts facilitated

by successful out-of-outclave manufacturing



• Out-of-Autoclave Composite Manufacturing methods include: – Vacuum Bag Only – Resin Transfer Molding (RTM) – Vacuum Assisted Resin Transfer Molding

(VARTM) – Balanced Pressure Fluid Molding – Microwave Curing – Prepreg compression molding – E-Beam Curing



20

Ceramic Matrix Composite Processes 3 Main Types: a. Chemical Vapor Infiltration (CVI)

1) Requires extensive facilitation (furnaces to deposit chemical composition of matrix phase through vapor infiltration)

2) Results in the fabrication of high quality CMC parts 3) Very economical process for large lots of parts but not

inexpensive for small lots b. Polymer Infiltration and Pyrolysis (PIP)

1) Facilitization requirements are not as extensive – matrix infiltration is very similar to OMC parts

2) Parts are usually of lower quality than CVI parts 3) Economical for small lots of CMC parts – quite costly for large

lots of parts c. Melt Infiltration (MI)

1) Requires special high temperature furnaces to melt silicon metal being infused into the prepreged composite

2) Parts can be very high quality 3) Process has not yet been used for large lots of parts; currently

cost lies between CVI and PIP ME 7502 Introduction - Dr. Brian J. Sullivan

C/SiC Overview

• 3000F + Temperature Capability • High Specific Strength • Non-Oxidizing Matrix • Matrix CTE Compatible with EBC • High Durability with EBC Coating

Environmental Barrier Coating

C Fiber Fiber/Matrix Interface Coating SiC CVI Matrix

C/SiC

Attributes

21 ME 7502 Introduction - Dr. Brian J. Sullivan

Photomicrograph from A. Calomino NASA GRC

C/SiC Microstructure


C/SiC Manufacturing Process

CVI Carbon Fiber

Interface

CVI SiC Protective Coating

CVI SiC Densifi-cation

Customer Design

Customer CTQ’s

Composite Design

Tooling and Process Design

Textile Processes

2D/3D

Heat Treat and

Prepreg

Machining

Preform Lay-up

& Tooling

Autoclave

C Fiber Pan or Pitch Inspection

C/SiC


Preforming Capability Fabric Cutters

Heated Presses

Autoclaves


CVI Reactors


CMC Machining Capability

Weldon CNC Cylindrical Grinder

HAAS VFZ Mill, 4-Axis CNC

HAAS VR II Mill, 5-Axis CNC


CMC Analysis, Testing & Inspection Capability IR NDE

Mechanical Testing

SEM

Optical Microscopy

CMM


C/SiC Manufacturing Process

CVI Carbon Fiber

Interface

CVI SiC Protective Coating

CVI SiC Densifi-cation

Customer Design

Customer CTQ’s

Composite Design

Tooling and Process Design

Textile Processes

2D/3D

Heat Treat and

Prepreg

Machining

Preform Lay-up

& Tooling

Autoclave

C Fiber Pan or Pitch Inspection

C/SiC

Tooling may be required


Preform Tooling Required: All Parts Types: Similar to Polymer Matrix Composites

• Materials Metals, Graphite, Plastic

• Design Concerns CTE, Debulk Pressure, Assy/Disassy

Release Applied

Preform Layup

Vacuum Debulk


CVI Tooling Required: During CVI PyC and 1st CVI SiC Types: Perforated Graphite

• Materials Purified Graphite

• Design Concerns CTE, Preform Pressure,

Assy/Disassy


Fabric Descriptions 2D Fabric • Balanced Plain Weave (MS5005900) • T300® 1K Tow (MS5005800) • Heat Treat: Maximum Use Temperature (MS5006900) • Prepreg: Fugitive Binder as a Manufacturing Aid (MS5007000)

50 yard rolls of fabric ready for Heat Treatment


Fabric Descriptions Draping 2D Fabric • Draping analyses performed on complex shapes • Shear maps used for ply design and layup • Plain weaves shear < satin weaves

Combustor Liner Draping Analysis

Combustor Liner Preform

T.E.A.M. Inc. textile engineering and manufacturing


Fabric Descriptions 3D Weave • Orthogonal, Angle and Layer Interlock Constructions • T300® 1K and 3K • Pros:

• Cons:

Angle Interlock

Layer Interlock Angle Interlock Fill View

Orthogonal

Size limitations due to limitations in weaving equipment Inplane property knockdown with minimal across-ply

property improvement

Can bias reinforcement No delaminations


Braids • 2D Braids • 3D Braids: Cartesian and Lockstep Processes • T300® 3K max (CVI Requirement) • Pros: Can conform to complex geometries • Cons: Size limitations due to limited number of braiding carriers

Fabric Descriptions

2D Flat Braid

2D Triaxial Braided Thruster and close-up of throat prior to machining


• Most common is carbon fiber reinforced carbon matrix (C-C) – aircraft brakes, rocket nozzles

• Carbon fiber reinforced silicon carbide matrix (C/SiC) – Space Shuttle TPS repair parts, rocket motor thrusters

• Silicon carbide reinforced silicon carbide matrix (SiC/SiC) – jet engine (flaps and seals, combustor liners) and turbine engine components (stator vanes)

35

Types of Ceramic Matrix Composites and their Applications




C/SiC Cover Plate Flexes to Conform to WLE

C/SiC Cover Plate

Concept Description • Flexible 7-in MCM-700 coated C/SiC

cover plates • Cover plates flex and conform to WLE

within 0 to 5 mils • TZM attach hardware coated with

R512E and MCM-700 • 20 to 30 unique plug geometries

required to provide coverage of all WLE panels to within 1” of T-seals

• Uncured NOAX edge sealant is being developed for edge gaps exceeding 20 mils

• Capable of repairing RCC damage with a maximum dimension of 6”

Status • 13 Plug Repair Panels on ISS • 6 additional Plug Repair Panels by

7/06

TZM Attach Hardware

Space Shuttle “Return to Flight” Plug Repair

Inserting Plug Assembly

Back View of Installed Plug Assembly


39

Aft end of the engine for the F-18 Super Hornet showing CMC flaps and seals after 500 sorties in Iraq War


40

CONSTITUENT & COMPOSITE PROPERTIES

MATRIX PROPERTIES (R.T.)

UTS (kpsi)UCS (kpsi)

THERMOSETS3.-10.20.-65.

620y

8.717Y

814.5Y

2.5-9.7.6Y

-5.580.7476.3

STEEL (1040) 0.28 30 85 (YP) 6ALUMINUM (7075-T6) 0.095 10 73 (YP) 13.3GLASS (1/2 in. ROD) 0.09 10 10 9GRAPHITE (BULK) 0.067 1.3 3 2.-4.*ACRYLONITRILE BUTADIENE-STYRENE

ρ (pci) E (Msi) α (µ°F-1)MATERIAL

440.330.038

0.058

0.4 30

33

0.049 1.3 14

0.044 .3-.6

THERMOPLASTICS

CERAMICS

0.043

EPOXY to 250°F

POLYIMIDE to 600°F

ACRYLIC

POLYESTER

ABS*

3.96

8.370.0828SILICON CARBIDE (SiC)

OTHER

4.21

ALUMINUM OXIDE (Al2O3) ALUMINA

0.112 8.19


41

FIBER PROPERTIES (R.T.)

MATERIAL ρ (pci) E (Msi) UTS (kpsi) α (µ°F-1)E-GLASS 0.092 10.5 500 2.8S-GLASS 0.09 12.4 650 1.6ARAMID-KEVLAR 29 0.052 9 550 -KEVLAR 49 0.053 19 550 -1.1GRAPHITE (TYPICAL) 0.066 33-75 425-250 -0.6BORON 0.1 60* 530* 2.7ALUMINUM OXIDE (Al2O3) 0.134 55 250SiC 0.112 60 550


42

COMPOSITE PROPERTIES FILLED EPOXY RESINS (PARTICULATE)

SMC (SHORT [0.5-2 in] FIBER/POLYESTER MATRIX)

FILLER wi, w/o E (Mpsi) SUT (ksi) SUC (ksi)

29 0.53 2.37 10.1844 0.73 3.38 10.3755 0.81 3.49 10.5129 0.51 2.47 10.0944 0.62 2.88 9.6829 0.47 2.76 9.4244 0.62 2.5 9.5

CaCO3

CLAY

SOLID GLASS SPHERES

2.36 10.46-NONE 0.37

FIBER vf v/o E1 (Mpsi) S1ut (ksi) (E2 ~ 0.8E1)GLASS 33 1.7 15 (S2ut ~ 0.8S1ut)

CARBON 35 3.9 15GLASS,

CARBON24, 26

3.5 17


43

FIBER COMPOSITE PROPERTIES vf = 0.6

[0] UNI. E1 (Mpsi) E2 (Mpsi) S1t (kpsi) S1

c (kpsi) S2τ

S2-GL/EP 7 2.0 220 130 8

HM GR/EP 32 1.4 200 180 7KEV 49/EP 12 1.0 200 40 4B/EP 36 3.6 250 360 13

[0/±45/90] Q/I Ex (Mpsi) Sxt (kpsi) ρw (pci)

S2-GL/EP 2.2 88 0.070HM GR/EP 9.0 80 0.055KEV 49/EP 4.0 60 0.047B/EP 10.0 100 0.073

[0/90] Ex/ρw (M*in) Sxt / ρw (k*in)

S2-GL/EP 64 1760H GR/EP 304 2040KEV 49/EP 138 1900B/EP 271 19201040 STEEL 107 3047075-T6 AL 105 768


44

COMPARISONS

[0/90] FIBER/EPOXY, Vf = 0.6

S2-GL/EP

KEV 49/EP

HM GR/EP

B/EP

7075-T6 AL

1040 STEEL

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

2.2

0 50 100 150 200 250 300 350

E x / ρ (M*in)

S UT /

ρ (M

*in)


45

COMPARISONS

Strength Vs. Temperature

0

20

40

60

80

100

120

140

160

180

0 500 1000 1500 2000 2500 3000 3500 4000

Temperature (°F)

Stre

ngth

(ksi

)

Steel 3D-Pitch Carbon-Carbon


46

SUMMARY GL/EP: GOOD STRENGTH/WEIGHT, CHEAP, NON-CONDUCTING (ELECTRICITY) LOW STIFFNESS/WEIGHT GR/EP: GOOD STRENGTH/WEIGHT, STIFFNESS/WEIGHT, ZERO AXIAL THERMAL EXPANSION, EXPENSIVE, FLAMMABLE, CONDUCTS ELECTRICITY KEV49/EP: GOOD TENSILE STRENGTH/WEIGHT, IMPACT RESISTANT, MODERATE COST ZERO AXIAL THERMAL EXPANSION, POOR COMPRESSIVE STRENGTH, MODERATE STIFFNESS/WEIGHT B/EP: GOOD STRENGTH/WEIGHT, STIFFNESS/WEIGHT, OUTRAGEOUSLY EXPENSIVE HYBRIDS: COMBINE REINFORCEMENT LAYERS TO ADVANTAGE CMC: EXCELLENT HIGH TEMPERATURE STRENGTH, HIGH CORROSION RESISTANCE


Documents

ME 7502 Lecture 1 - Dr. Brian Sullivanvucoe.drbriansullivan.com/wp-content/.../Lecture-1... · ME 7502 Introduction - Dr. Brian J. Sullivan 1 • Definitions • Particulate Composites