P10229: Composites Autoclave

Brian Cario: MEMatt Brady: ME

Matt DiFrancesco: MEBrandon Allen: EE

John Mink: EE

2

Background: Purpose of an Autoclave

• Device for Curing Components Made of Composite Materials Under Heat and Pressure

• High-Strength, Low Mass• Very Low Void Ratio• 10x Wet Layup

Image Courtesy directindustry.com

3

Project Objectives Senior Design 1 Senior Design 2

Tasks Concept Generation and SelectionComplete Pressure Vessel Construction

Detailed Design, Ready for Construction

Test Pressure Vessel

Spec Stock Parts Final Assembly

Test Autoclave

Deliverables Complete Autoclave Design Complete, Operable Autoclave

Partially Built Pressure Vessel Manual for Operation

Some Parts Obtained

4

Benchmark: ASC Process Systems Econoclave

• 22” Dia x 48” Long Working Volume• 200psig Max Pressure• 500oF Max Temperature• 5oF Temp Uniformity• PC User Interface• Electric Heat• Extensive Safety Systems• Fast-Closing Door• Priced from $85k-$120k plus delivery and setup

5

Potential Users of an Autoclave at RIT• MET Department--Student Projects

• Proposed location: Composites Lab• Student Teams: Baja, Formula, Aero• ME Department for Research• CIMS• Future Senior Design Groups• Anyone Needing a super lightweight structure• Possible Outside Users• Future, Unforeseen Uses

6

Why Have an Autoclave at RIT?

• Strong lightweight components are becoming increasingly important

• Rented Autoclave Time is Rare and Expensive• Production-Scale Utility Bills can reach $750/run• On-Site Option Offers Convenience• Could be Customized for Other Future Uses• Learning Tool• Enables Ongoing, Long-Term Research• Renting Time Could Generate Funding

P10229 Econoclave

Working Diameter 20" 22"

Working Length 48" 48"

Max Temp 400F 500F

Max Pressure 150psig 200psig

Door Flange Fast-Close

Interface PC-Based PC-Based

Heating 240V 480V

Pressurization Nitrogen Optional

Certification RGE-Tested ASME

Safety Systems Designed Standard

Total Cost $9K $85K ++

Feature-Cost Comparison to ASC Econoclave; Closest Competitor

Bill Of Materials Part IElectrical

Description Part Number Source Quantity Unit Price Total PriceHigh Temperature Wire TBD Goodman's 50' roll $27.50/50ft $27.50Back Panel (22”x22”) N/A Plastics Lab 9 Free FreeDC Relays N/A Plastics Lab 3 Free FreeDin-rail/Terminals N/A Plastics Lab 9 Free FreeHigh Current Bulkhead Connector 1575 Pave Technology Co 1 $90.00 $90.009 #22AWG Bulkhead Connector 1588 Pave Technology Co 2 $115.00 $230.00Thermistor 502JH1k US Sensor 5 $10.00 $50.003-Phase 45A Relay GA312D45Z Crouzet 1 $132.29 $132.2922 AWG Red Wire 22awgRed Chrome Glow 50ft $0.25/ft $12.5022 AWG Black Wire 22awgBlack Chrome Glow 50ft $0.25/ft $12.503-Phase 240V Safety Switch 7524K22 McMaster 1 $83.89 $83.89

Subsystem Total $638.68

Pressure Vessel and StandDescription Part Number Source Quantity Unit Price Total Price2" x 2" x 1/4" (48" length) A36 HR Angle Steel N/A Rochester Steel and Surplus 13 $9.00/ Section $117.0024" x 48" (3/16 thick) A36 HR Sheet Steel N/A Rochester Steel and Surplus 1 $45.00 $45.00Titan 6" Casters with full brake 5500398 Tractor Supply 4 $29.99 $119.961.25" x 1' A36 HR Steel Bar R12 Metals Depot 1 $12.01 $12.01Rust-Oleum Hammer Black Paint 170995 Lowes 2 $14.98 /qt $29.965/16 - 18 x 1" Hex Bolts 48872 Lowes 1 $3.18 /25 $3.185/16 - 18 Hex Nuts 40958 Lowes 1 $4.51 /25 $4.512' x 2' x 1/2" A36 Steel Plate P112 Metals Depot 1 $125.76 $125.762' x 8' x 3/64" 3003 Aluminum Sheet S3040 Metals Depot 3 $40.96 $122.881/8" x 1/8" Aluminum Rivet 45309 Lowes 1 $4.94 /100 $4.94Tested RG&E Vessel Parts and Labor - RG&E 1 $3,700.00 $3,700.00 Includes ~$2500 in parts Gas Cylinder Clamp 2283T12 McMaster 1 $40.12 $40.12Mesh for Part Rack 9243T381 McMaster 1 $59.02 $59.02Door Hinge Bushing 2938T62 McMaster 2 $4.65 $9.30Door O-Ring 9396K418 McMaster 2 $22.91 $45.82

Subsystem Total $4,439.46

ControlsDescription Part Number Source Quantity Unit Price Total PricePressure Transducer PX91N0-10KSV Omega 1 $860.00 $860.00Standard Power Supply iDRN-PS-1000 Omega 1 $150.00 $150.003-Phase Circuit Breaker QO340 Schneider-Electric 1 $240.00 $240.00Relay 501-00010 MPJA 1 $19.95 $19.95Computer EL1600-01 eMachines 1 $229.99 $229.99DAQ NI USB-600 National Instruments 1 $169.00 $169.00

Subsystem Total $1,668.94

PressurizationDescription Part Number Source Quantity Unit Price Total PriceNitrogen Regulator 7897A12 McMaster 1 $137.88 $137.88Inlet Solenoid Valve 10M61 Magnatrol 2 $153.00 $306.00Blow-off Valve 4673K71 McMaster 1 $104.23 $104.2336" Nitrogen Inlet Hose 5676T846 McMaster 1 $66.39 $66.391.5"x3/8" Pipe Bushing 4638K575 McMaster 1 $5.13 $5.136 feet 3/4" Copper Tube 8967K8 McMaster 1 $25.27 $25.273/4" NPT Compression Fitting 5272K294 McMaster 1 $11.85 $11.853/8" MxF Stainless Braided Hose 5676T342 McMaster 1 $41.26 $41.263/4" x 3/8" Reducing Tee 44605K468 McMaster 1 $4.25 $4.253/4" NPT Nipple 7736K114 McMaster 1 $13.47 $13.472"x3/4" Pipe Bushing 44605K295 McMaster 1 $6.53 $6.533/8" Pipe Nipple 7727K162 McMaster 2 $3.47 $6.941-200psi hi-temp Pressure Gauge 4010K116 McMaster 1 $108.58 $108.583/8" Pipe Tee 44605K402 McMaster 2 $6.09 $12.181.5" Pipe Elbow MxF 44605K138 McMaster 1 $7.11 $7.11

Subsystem Total $857.07

Heating, Circulation, and InsulationDescription Part Number Source Quantity Unit Price Total PriceMineral Wool Insulation, 2"x2'x4' qty. 6 N/A ATS Acoustics 3 $34.00 $102.004kW Straight Incoloy tubular heating elements THE04061 Tempco 3 $131.05 $393.15bulkhead connectors for heating elements ? Tempco 3 $34.95 $104.855-blade fan, 1000CFM, CW rotation 2UJU3 Grainger 1 $19.71 $19.711/50 HP 115VAC Motor for fan 58459 Drill Spot 1 $38.46 $38.465/16" shaft seal 13125K76 McMaster 1 $20.13 $20.133/8" flanged bearing for fan shaft 9440T18 McMaster 1 $1.56 $1.561"OD, .5"ID steel tube for fan shaft support T21250 Metals Depot 1ft $9.01 $9.013/8" 1018 steel rod R238 Metals Depot 2ft $2.46 $2.461/4" shaft coupler 6412K11 McMaster 1 $5.44 $5.44Galvanized steel plug for blower shaft mount 7739K188 McMaster 1 $6.00 $6.001x3x11ga. Steel Tube for motor mount T13111 Metals Depot 2ft $6.96 $6.9611 gage steel sheet for heating element mounts S111 Metals Depot 1ftx2ft $21.40 $21.40

Subsystem Total $731.13

Autoclave Total $8,335.28

Funding Options• Current funds: $4000: Pressure Vessel, Incomplete

Stand, Completely designed system• $4500: Complete Pressure Vessel and Complete Stand• $6000: Complete Pressure Vessel, Stand, Heating

System, and Pressurization System• $8500: Complete Autoclave as Designed

• Design will have all the basic functionality of commercial unit at 1/10 the cost