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Structural
Thermal
Frictional (Brakes)
Ablative/Nozzles
1 ME 7502 Introduction - Dr. Brian J. Sullivan
Aerospace Space Marine Civil Engineering Automotive Recreational
2 ME 7502 Introduction - Dr. Brian J. Sullivan
Aerospace
3 ME 7502 Introduction - Dr. Brian J. Sullivan
Typical Aerospace Composite Applications
Cockpit components
Doors
Interiors: sidewall, ceiling and floor panels; storage and cargo bins; lavatories and galleys
Nose cones
Wheel brakes
Air conditioning ductwork
Engine components and cowlings
Pylon fairings
Leading edge slats
Ailerons
Flaps, spoilers and deflectors
Exteriors: Fuselage components
Access panels
Tail planes and elevators
Fin boxes and rudders
4 ME 7502 Introduction - Dr. Brian J. Sullivan
Airbus’ Innovative Use of Composites
Spoilers Center wing box
Horizontal tail
Vertical tail
Fuselage section
5 ME 7502 Introduction - Dr. Brian J. Sullivan
Commercial Aerospace
6 ME 7502 Introduction - Dr. Brian J. Sullivan
Military Fixed Wing
Cytec Engineered Materials Proprietary 7 ME 7502 Introduction - Dr. Brian J. Sullivan
8 ME 7502 Introduction - Dr. Brian J. Sullivan
Extensive use of Composites in Rotorcraft Applications
9 ME 7502 Introduction - Dr. Brian J. Sullivan
Business & Regional Jets
Cytec Engineered Materials Proprietary 10 ME 7502 Introduction - Dr. Brian J. Sullivan
Composites (plus skins)
F-22 Raptor 25% composite by weight
Composite usage on the F-22
Weight reduction - specific strength
Temperature performance
Stealth characteristics
Radar transparency
Lower cost 11 ME 7502 Introduction - Dr. Brian J. Sullivan
Marine Applications Rigid and flexible oil & gas
tubulars • Bulk chemical storage tanks • Racing sailboat hulls and
equipment.
13 ME 7502 Introduction - Dr. Brian J. Sullivan
Civil Engineering Applications
Repair, upgrading and retrofit of bridges, buildings and parking decks.
Selective use in composite bridge decks. Engineered lumber reinforcement
14 ME 7502 Introduction - Dr. Brian J. Sullivan
Commercial Automotive Applications
Light Truck Drive Shafts Air Bag Propellant Filters NGV Tanks Aftermarket (cosmetic parts,
brake pads) Race Car Body/Chassis,
Brakes and Clutches Motorcycle Drive Belts
15 ME 7502 Introduction - Dr. Brian J. Sullivan
Harley-Davidson
16 ME 7502 Introduction - Dr. Brian J. Sullivan
17 ME 7502 Introduction - Dr. Brian J. Sullivan
Automotive
18 ME 7502 Introduction - Dr. Brian J. Sullivan
Automotive
19 ME 7502 Introduction - Dr. Brian J. Sullivan
Recreational Applications
Tennis racquets and shoes Golf club shafts Fly fishing rods Bicycle frames and stems Snowboards Hockey sticks and skates Arrow shafts Baseball bats …...
Thornel T-300 carbon fibers have been used in a wide variety of recreational applications, including:
20 ME 7502 Introduction - Dr. Brian J. Sullivan
Bicycle and components
21 ME 7502 Introduction - Dr. Brian J. Sullivan
Ski Poles and Skis
23 ME 7502 Introduction - Dr. Brian J. Sullivan
Wind Turbine Blades
24 ME 7502 Introduction - Dr. Brian J. Sullivan
Structural
Thermal
Frictional (Brakes)
Ablative
25 ME 7502 Introduction - Dr. Brian J. Sullivan
2X2X-- CuCu3X3X
4X4X5X5X
6X6X
1
10
100
1000
10000
0.01 0.1 1 10 100
Electrical Resistivity (µ-ohm-m)
Ther
mal
Con
duct
ivity
(W/m
K)
T-300
P-25
T-50
P-55
P-75
P-100P-120
K-1100
Vapor Grown, HTHOPG
Cu
AlMg
Ti
6xCu
3xCu
2X2X-- CuCu3X3X
4X4X5X5X
6X6X
1
10
100
1000
10000
0.01 0.1 1 10 100
Electrical Resistivity (µ-ohm-m)
Ther
mal
Con
duct
ivity
(W/m
K)
T-300
P-25
T-50
P-55
P-75
P-100P-120
K-1100
Vapor Grown, HTHOPG
Cu
AlMg
Ti
6xCu
3xCu
High Thermal Conductivity
Thermal Conductivity 2 to 3 times that of Copper
Comparison of Thermal and Electrical Behavior of Graphite 26 ME 7502 Introduction - Dr. Brian J. Sullivan
Space Applications - UHM Pitch Fibers
Lightweight satellite bus structures
Satellite antennae Solar array panels High modulus
stiffeners Avionics enclosures
27 ME 7502 Introduction - Dr. Brian J. Sullivan
Electronics Thermal Applications
Heat Dissipation Devices Clips & enclosures Heat sinks Heat pipes Thermal planes Circuit boards
28 ME 7502 Introduction - Dr. Brian J. Sullivan
Metal Matrix Cast Composites, Inc.
Discontinuous Graphite Reinforced Aluminum and Copper Example Products
Cu/Gr Power
Electronic Packaging
Al/Gr Electronic Assembly
Manufacturing Components
Al/Gr Structural Aerospace
Components
WWW.MMCCINC.COM 29 ME 7502 Introduction - Dr. Brian J. Sullivan
LMA TG 8000 TWTA Project
TWTA Units and Associated Electronics
High Gain Antenna Structure.
30 ME 7502 Introduction - Dr. Brian J. Sullivan
Thermal Devices
31 ME 7502 Introduction - Dr. Brian J. Sullivan
Structural
Thermal
Frictional (Brakes)
Ablative
32 ME 7502 Introduction - Dr. Brian J. Sullivan
• Applications – Comm. Aircraft Brakes: 777, 767,
MD-11, MD-90, Fokker 100/70, Saab 340
– Military Aircraft Brakes: B-2, F-14, F-15, F-16, F-18, F-117, and C-17
– Automotive Brakes: – Formula 1, GT and high
performance production automobiles
Brake Applications
33 ME 7502 Introduction - Dr. Brian J. Sullivan
Carbon/Carbon Brakes
34 ME 7502 Introduction - Dr. Brian J. Sullivan
Aircraft Brakes
Qualified on Major Programs Commercial Aircraft - 767, 777, MD11,
MD-90, A-330, A-340, Fokker 100
Military - F14, F-15, F-16, F-18, F-117, B-2
Business aircraft- Saab 340, Astra SPX, Falcon 900, Challenger 604
35 ME 7502 Introduction - Dr. Brian J. Sullivan
Carbon/Carbon Brakes and Clutches
Aircraft brakes are based primarily on P-25 2K and 4K.
Formula 1 race car brakes and clutches based on other pitch fiber products.
Engineered preform technology advancing rapidly
36 ME 7502 Introduction - Dr. Brian J. Sullivan
Structural
Thermal
Frictional (Brakes)
Ablative/Nozzles 37 ME 7502 Introduction - Dr. Brian J. Sullivan
Launch Vehicles and Missiles
Qualified on Major Programs Rocket nozzles: Space Shuttle, Delta
II, III, & IV, Atlas, Pegasus, Castor (H2A), Titan
Missiles: Minuteman Refurbishment, Trident, Navy Standard, Patriot, Hawk, Hellfire
38 ME 7502 Introduction - Dr. Brian J. Sullivan
Carbon/Carbon Rocket Nozzel
39 ME 7502 Introduction - Dr. Brian J. Sullivan
Design Cycle for Composite Structures
40
The design cycle for composite structures introduces the requirement to design the material as well as the structure.
ME 7502 Introduction - Dr. Brian J. Sullivan
41
Structural Designer Has To Identify Material Geometry Attachments Fabrication Procedure CMC Designer Further Specifies Fibers, Matrix, And Other Constituents Fiber Architecture And Preforming Technique
Design of Ceramic Matrix Composites
ME 7502 Introduction - Dr. Brian J. Sullivan
42
Design Requirements Selection of Constituents
Preforming & Fiber Architecture
Micromechanics & Theoretical Database
Thermostructural Analysis
Material Characterization And Subcomponent Testing
Composite Design Procedure
ME 7502 Introduction - Dr. Brian J. Sullivan
43
OPERATING ENVIRONMENT Maximum Temperature Mechanical Loads Thermochemical Environment Lifetime DESIGN GOALS Minimum Cost Minimum Weight Maximum Performance Optimize Application
Design Requirements
ME 7502 Introduction - Dr. Brian J. Sullivan
44
Maximum Use Temperature
Fiber
Tem
pera
ture
, °C
0
500
1000
1500
2000
2500
3000
3500
4000
Nex
tel 7
20 (C
reep
)
Tyra
nno
LOX
M
Nic
alon
(CG
)
T300
Gra
phite
(n
onox
idiz
ing)
CONSTITUENTS Fibers Matrix Fillers Fiber/Matrix Interface Coatings SELECTION CRITERIA • Thermostructural Properties • Thermochemical Behavior • Cost, Availability • Size, Handleability
Selection of Constituents Thermochemical Stability
ME 7502 Introduction - Dr. Brian J. Sullivan
45
Approach
PREFORM FABRICATION Hand Lay Up Filament Winding & Fiber Placement 2D Weaving & Braiding Multidirectional Weaving & Braiding FIBER ARCHITECTURE Fiber Volume Fraction Fiber Orientation Fiber Proportions
Preform Fabrication And Fiber Architecture
ME 7502 Introduction - Dr. Brian J. Sullivan
46
Approach
Matrix Modulus, Msi
20 30 40 50
Com
posi
te M
odul
us, M
si
0
10
20
30
40
50
DirectionAirfoil Radialvf = 0.40Multi-D Braid
36.6 Msi
36.5 Msi
SCS6-Nicalon/ SiC
Matrix Modulus
Composite Modulus
EFFECTIVE MATRIX MODULUS
Models Based On Fundamental Elasticity • Hashin, J. Appl. Mech, Sept. 1979 • Jones, Mech of Composite Matls, 1975 • Rosen, ASTM, STP 617, 1977 • Pagano, Composite Sci. and Tech, 1988. Data Correlation • Theoretical Model Correlated With Available Data • Theory Exercised For Properties Vs. Fiber Architecture
Micromechanical Modeling
ME 7502 Introduction - Dr. Brian J. Sullivan
47
Effects of Fiber Architecture
Axial Tensile Strength
Braid Architecture
Axia
l Ten
sile
Stre
ngth
(ksi
)
0
10
20
30
40
50
60
70
80 Braided C/SiCvf = 40 percentT = 2000°F
45-7
5
45-5
0
45-2
5
80-2
5
80-5
0
80-7
5
60-2
5
60-5
0
60-7
5Hoop Tensile Strength
Braid Architecture
Hoo
p Te
nsile
Stre
ngth
(ksi
)
0
10
20
30
40
50
60
70Braided C/SiCvf = 40 percentT = 2000°F
45-7
5
45-5
0
45-2
5
80-2
5
80-5
0
80-7
5
60-2
5
60-5
0
60-7
5
a Braid designation identifies braid angle and proportion of braiding fibers, i.e., 45-75 implies 45° braid angle (0°=axial) and 75 percent braid fibers.
Micromechanical Modeling
ME 7502 Introduction - Dr. Brian J. Sullivan
48
Modeling Issues
ANSYS 5.5.3 JUN 21 200011:51:18 ELEMENTS
1 2
X
Y
Z
XV =-.819735 YV =.300779 ZV =.487408
*DIST=7.145 *XF =2.502 *YF =5.481 *ZF =-3.347 A-ZS=-11.918 PRECISE HIDDEN
XY
Z
WIND=2 XV =-.82 YV =.3 ZV =.5
*DIST=1.666 *XF =-.973536 *YF =3.887 *ZF =-6.31 A-ZS=-2.033 PRECISE HIDDEN
• Include Effects of Anisotropy • Couple Transient Heat Transfer & Stress Analysis • Compute Stresses At Times Of: - Maximum Thermal Gradient - Maximum Mechanical Load - Maximum Temperature - Critical Events • Define Design Stress - Matrix Cracking (SiC-Based) - Creep Stress (Oxide/Oxide) • Maximum Stress Failure Criterion
Thermostructural Analysis
ME 7502 Introduction - Dr. Brian J. Sullivan
49
Optimized Fiber Architecture
80-75 Braid Margins of Safety
Mar
gin
of S
afet
y
0
1
2
3
4
Axi
al
Hoo
p
Thru
-Thi
ckne
ss
Inte
rlam
inar
She
ar80-50 Braid Margins of Safety
Mar
gin
of S
afet
y
0
1
2
3
4
Axi
al
Hoo
p
Thru
-Thi
ckne
ss
Inte
rlam
inar
She
ar
80-25 Braid Margins of Safety
Mar
gin
of S
afet
y
0
1
2
3
4
Axi
al
Hoo
p
Thru
-Thi
ckne
ss
Inte
rlam
inar
She
ar
Margins of Safety = Strength/Stress - 1 Select Fiber Architecture For Balanced Margins of Safety
Thermostructural Analysis
ME 7502 Introduction - Dr. Brian J. Sullivan
50
Test Critical Properties
• Thermostructural Analysis Defines Critical Properties And Temperatures • Property Tests Must Address Anisotropy, Specimen Size, Fiber Architecture • Correlate Micromechanical Model • Use Model To Compute Consistent Orthotropic, Temperature Dependent Properties
Material Characterization
ME 7502 Introduction - Dr. Brian J. Sullivan
51
Test Critical Design Features
Subcomponent Testing
• Confirm Design With Subcomponent Tests - Critical Loads And Design Features, e.g. attachment regions • Analyze Subcomponent Test To Insure Test Matches Operation • Predict Behavior Prior To Test • Perform Post-Test Data Correlation
Test run on May 13, 2004 in DFRC Flight Loads Lab.
Photo taken at 2400° F. Orange glow is test article emitting visible light. Sensors can be seen as shadows
on test article. ME 7502 Introduction - Dr. Brian J. Sullivan
52
MATRIX ALGEBRA
{ }
[ ]
[ ] kl
ij
k
I
aaaaaaaaaa
a
xxxx
x
δ;100010001
;
;
333231
232221
131211
3
2
1
=
=
=Column matrix:
Square matrix:
Unit matrix:
Diagonal matrix: [ ]
[ ]
=
=
000000000
0
000000
33
22
11
dd
dd
Null matrix:
TYPES:
ME 7502 Introduction - Dr. Brian J. Sullivan
53
MATRIX OPERATIONS
[ ] [ ] [ ] [ ]
[ ][ ] [ ][ ]
[ ] [ ] [ ]( ) [ ][ ] [ ][ ] [ ][ ] [ ][ ][ ] [ ][ ] [ ] [ ]{ } { } ilil
jkjkij
dxacolcolsqaIaaIcbasqsqsqbcacbac
abbabababababababababababa
ba
abbabababa
ba
====
==+=+
≠
++++++++
=
+=
++++
=+
321
322322221221312321221121
321322121211311321121111
22222121
12121111
.........
...
...
.........
...
...
[ ][ ] [ ] ,cba = [ ] [ ] [ ] [ ] [ ][ ] 11 , −− == bcacab
Addition (subtraction):
Multiplication:
If then
Transpose [ ] jiTij
T aaaaaaaaaaa
a =
=
332313
322212
312111
ME 7502 Introduction - Dr. Brian J. Sullivan
54
Matrix Inverse
Cofactor
Determinant
Inverse
[ ]
( )[ ]
[ ] ( )[ ]
[ ] [ ] [ ][ ] [ ] { } { }
{ }
{ } [ ]{ } { }{ }
{ }{ }
[ ] [ ][ ] [ ]
{ }{ }
{ } [ ]{ } [ ]{ } { } [ ]{ } [ ]{ }βαδβαγ
βα
δγ
δγ
δδδγγγ
βα
βββααα
dcba
dcba
feg
fdcba
dc
dcbaaabaaabbbaaa
e
aaCofa
subaasubaasubaasubaa
aCof
aaaaaaaaaaaaaaaaaDet
T
+=+=
=
=
==
=
=
=
=
=
=
−+−+−==
−
;
;
321321
;
..........................................
......
......
.........
...
...
)()()(
3
2
1
3
2
1
3333
1111
33333231
23232221
131211131211
1
22222121
12121111
312232211333213123123223332211
Partitioning
ME 7502 Introduction - Dr. Brian J. Sullivan
55
Best bet:
USE MATHCAD
ME 7502 Introduction - Dr. Brian J. Sullivan
