P10229P1022920092/200920092/2009

33Composites AutoclaveComposites AutoclaveBrandon Allen (EE) <> Matt Brady (ME) <> Brian Cario (ME) <> Matt DiFrancesco (ME) <> John Mink (EE)Brandon Allen (EE) <> Matt Brady (ME) <> Brian Cario (ME) <> Matt DiFrancesco (ME) <> John Mink (EE)

Chris DeMinco (Faculty Guide) <> Carl Lundgren (Sponsor) <> Rob Aldi (Sponsor)Chris DeMinco (Faculty Guide) <> Carl Lundgren (Sponsor) <> Rob Aldi (Sponsor)

Mission Statement:Mission Statement:To design a composites autoclave to be able to hold 150psi at a temperature of 400 degrees Fahrenheit. The vessel should To design a composites autoclave to be able to hold 150psi at a temperature of 400 degrees Fahrenheit. The vessel should be built to be able to maintain 15psi with intent to add additional features designed by future Multidisciplinary Senior Design be built to be able to maintain 15psi with intent to add additional features designed by future Multidisciplinary Senior Design projects.projects.

Background:Background:A composites autoclave is a vessel that can hold pressure at a desired temperature in an effort to create composite A composites autoclave is a vessel that can hold pressure at a desired temperature in an effort to create composite materials, including carbon fiber, that are lighter and stronger than their steel counterparts.materials, including carbon fiber, that are lighter and stronger than their steel counterparts.

Motivation:Motivation:Production models with minimal options start at upwards of $85,000, but this autoclave will be developed at 1/10 the cost Production models with minimal options start at upwards of $85,000, but this autoclave will be developed at 1/10 the cost with most of the functionality. The increased strength and weight savings by creating composite materials in the autoclave with most of the functionality. The increased strength and weight savings by creating composite materials in the autoclave also provides great opportunities for the RIT SAE Teams to use cutting edge technology.also provides great opportunities for the RIT SAE Teams to use cutting edge technology.

Additional Information:Additional Information:For additional information, please visit our teams website at:For additional information, please visit our teams website at: http://edge.rit.edu/content/P10229/public/Home http://edge.rit.edu/content/P10229/public/Home

What is an autoclave?What is an autoclave?An autoclave serves many purposes in many different An autoclave serves many purposes in many different applications from automotive to the aerospace industries. applications from automotive to the aerospace industries. By creating an increased temperature and increased By creating an increased temperature and increased pressure environment, resin systems cure better, creating pressure environment, resin systems cure better, creating stronger bonds and therefore a stronger part.stronger bonds and therefore a stronger part.

How will this benefit RIT?How will this benefit RIT?RIT clubs and student organizations, like RIT Baja SAE, will RIT clubs and student organizations, like RIT Baja SAE, will be able to create strong, light parts for their applications be able to create strong, light parts for their applications without needing to depend on outside sources to help them without needing to depend on outside sources to help them complete their tasks. When they need to make a last complete their tasks. When they need to make a last minute part, the autoclave will be at their disposal ready to minute part, the autoclave will be at their disposal ready to create their new A-arm or other critical components to create their new A-arm or other critical components to make their team a success. Other benefits include:make their team a success. Other benefits include:

-Student Projects-Student Projects-Classroom Experience-Classroom Experience-Potential Outside Investors-Potential Outside Investors

Where will it be located?Where will it be located?The autoclave will be located in the Composites Lab in The autoclave will be located in the Composites Lab in Building 78. This room provides room for expanding on Building 78. This room provides room for expanding on current capabilities with the availability of 230V, 3-phase current capabilities with the availability of 230V, 3-phase power for heating, and a fume hood for proper ventilation power for heating, and a fume hood for proper ventilation of composite gases.of composite gases.

A Special Thanks:A Special Thanks:All of us on the Composites Autoclave Team would like to thank the following people and organizations for all of their support.All of us on the Composites Autoclave Team would like to thank the following people and organizations for all of their support.

Autoclave Specifications:Autoclave Specifications:-150psi maximum pressure-150psi maximum pressure -400-400OOF maximum temperatureF maximum temperature -Exterior will be a safe -Exterior will be a safe temperaturetemperature-2' diameter by 5' deep-2' diameter by 5' deep to touch to touch

Test Specifications:Test Specifications:The autoclave was hydrostatically tested to 300psi and all The autoclave was hydrostatically tested to 300psi and all components will be tested to 450components will be tested to 450OOF and 300psi to make sure F and 300psi to make sure that no devices will fail.that no devices will fail.

Future Additions:Future Additions:

Rob Aldi (MET '09)Rob Aldi (MET '09)Carl Lundgren (MET)Carl Lundgren (MET)

Dr. Edward Hensel (ME)Dr. Edward Hensel (ME)Dan Johnson (MET)Dan Johnson (MET)Raymond SchlosserRaymond Schlosser

Electrical ControlElectrical ControlA complete electrical integration will be implemented so that A complete electrical integration will be implemented so that pressure and temperature can be changed with the push of a pressure and temperature can be changed with the push of a button. The ability to interface with a National Instruments button. The ability to interface with a National Instruments Data Acquisition unit was a main focus of the electrical Data Acquisition unit was a main focus of the electrical design, so that further information can be gathered and design, so that further information can be gathered and displayed for the user.displayed for the user.Bulkhead connectors are also available for feeding electrical Bulkhead connectors are also available for feeding electrical signals into the vessel. The connectors are made by PAVE signals into the vessel. The connectors are made by PAVE Technology Co. and are guaranteed to work at our 150psi, Technology Co. and are guaranteed to work at our 150psi, 400400OOF requirements.F requirements.

Heating SystemHeating SystemThree incoloy heating elements, one per leg of the 3-phase Three incoloy heating elements, one per leg of the 3-phase supply, will supply the chamber with enough heat to reach supply, will supply the chamber with enough heat to reach 400400OOF, aided by a blower in the back of the autoclave to F, aided by a blower in the back of the autoclave to increase air flow. A typical ramp rate of at least 5-10increase air flow. A typical ramp rate of at least 5-10OOF per F per minute will be obtained.minute will be obtained.

Computer ControlComputer ControlIntegrating a NI-DAQ and a Desktop Computer allows the Integrating a NI-DAQ and a Desktop Computer allows the operator to create multi-step processes which can be saved operator to create multi-step processes which can be saved and easily reused at a later date. This also offers a GUI which and easily reused at a later date. This also offers a GUI which contains all data essential to the autoclave operation. This contains all data essential to the autoclave operation. This control can translate directly into both more power and control can translate directly into both more power and easier use for the operator.easier use for the operator.In addition the user will be provided with up-to-date In addition the user will be provided with up-to-date information about the conditions inside of the autoclave. information about the conditions inside of the autoclave. This will allow the user to adjust conditions or stop the This will allow the user to adjust conditions or stop the autoclave if an error is to occur.autoclave if an error is to occur.

FEA Analysis:FEA Analysis:Finite Element Analysis was performed on all Finite Element Analysis was performed on all

structural components using Cosmos. The structural components using Cosmos. The components used to fabricate the pressure components used to fabricate the pressure vessel are all approved by the manufacturer vessel are all approved by the manufacturer

to withstand pressures in excess of the to withstand pressures in excess of the project goals, which was confirmed by this project goals, which was confirmed by this analysis. The pressure vessel tank has a analysis. The pressure vessel tank has a

factor of safety of 3.64 at 150psig and the factor of safety of 3.64 at 150psig and the door has a factor of safety of 3.40 under the door has a factor of safety of 3.40 under the same conditions. All other components have same conditions. All other components have

even greater factors of safety. A factor of even greater factors of safety. A factor of safety of at least 2 was physically verified by safety of at least 2 was physically verified by hydrostatically testing the completed vessel hydrostatically testing the completed vessel

to 300psig.to 300psig.

Hydrostatic Testing:Hydrostatic Testing:

0 50 100 150 200 250

0

50

100

150

200

250

300

350Pressure Over Time

Time (Minutes)

Pre

ssu

e (

psi

)

0 50 100 150 200 250

17

17.5

18

18.5

19

19.5

20

20.5Temperature Over Time

Time (Minutes)

Te

mp

era

ture

(D

eg

. C)

Results:Results:The vessel successfully held more than The vessel successfully held more than 300psi for 4 hours, losing only about 2.5psi. 300psi for 4 hours, losing only about 2.5psi. This loss would have been minimized had This loss would have been minimized had the test been run longer as the change in the test been run longer as the change in temperature was still causing the pressure temperature was still causing the pressure to ramp back up at the end of the test.to ramp back up at the end of the test.