Introduction to Advanced Composite Materials

Global Hawk UAV

An introduction to
composites:
!  modern composites defined
matrix of resin +fiber

!  advanced composites
> strength : weight ratio
specific purpose design

!  composite history & evolution

60 yrs of accelerating advances
fiberglass
epoxy matrix
carbon fiber
aramid fibers
advanced composites
aircraft applications
ceramic & metal matrix materials
repair techniques
 Composite
!  Transportation
applications
Ground, air, marine, space

!  Military
armor, weapons, containers

!  Sporting goods
golf, tennis, fishing, helmets,
wheels, skis/snow boards, kite and
wind surfing, snow machines, gun
components

!  Building materials
pipes, beams, panels, bridges,
roofing, decking, signs, furniture

!  Medical
prosthetic devices, braces,
enclosures, body moving aids
Other industries
! Electrical & electronics-
standoffs, circuit boards, junction
boxes, ladder rails, cherry picker
buckets

! Corrosion resistant
systems- oil field pipes, pump
bodies, suction rods

! Appliances & equipment-

compressor bases, washing
machine gears and parts, power
tool housings, computer housings

! Renewable Energy
systems- wind, ocean, solar
Composite pros & cons
! advantages
stiffness, TS/p, high fatigue life,
corrosion resistant,
complex shapes,
smooth skin, stealth,
multiple mfg methods

! Disadvantages
high labor, material and capital
costs,
storage of materials
damage and repairs
safety concerns
 Course Development

!  Industry needs Lay-Up with splice

•  workforce trained in composite usage
•  work experience using composites
•  design experience with composites
•  repair experience with composites
!  Students needs
•  hands on experience with composites
•  Students who want to work in growing
advanced composite industries
•  Design experience using composites
!  College needs
•  New technologies for students
•  New courses for program development
•  New laboratory ideas & equipment
•  Internships and industry partnerships

• 
Industry connections
! Training for new employees and
educational upgrades
! Internships for students and
faculty
! Research ideas for faculty and
students
! Industry tours for processing
classes
! Projects for capstone classes and
senior projects
! Feedback from employed alumni
! Development of training programs
! Equipment and lab material
donations
! Expertise for developing
programs and ideas
Industry ideas
! Review product, processes.
Materials, inspection and repair
techniques
• Cessna
• Monaco and Country Coach
• ECS Case
• Bayliner
• Boeing
• Erickson Air Crane
! Tooling
! Lean
! GD&T
! Six sigma
! CAD/CAM
! Automated systems
! Communication skills
! Material conveyance
! Repair
! Testing and Inspection
Course Outline
! Introduction to composites
! Advanced composites ( high temp/
high performance)
! Environmental effects on composites
! Fiber reinforcements
! Composite design considerations
! Tooling
! Inspection and testing
! Adhesive bonding
! Advanced composite assembly
! Liquid molding
! Industries and processes using
advanced composites
! Repair of composites
! Nanocomposites
 Laboratory Development
Laboratory experiments
•  Wet lay up-flat
•  Build a clip board
•  Build a mold & mold prep
•  Wet lay up with clocking in a
mold
•  Prepreg layup with clocking in
mold
•  De-bulking vac bag
•  Make a product (skate board
or surf board)
•  Resin transfer molding
experiment
 Lab Equipment

•  Benches
•  Freezer
•  Vacuum pump
•  Hand tools
•  Safety equipment
•  Furnace/autoclave
•  thermocouples
 Safety

•  Identify safety hazards and

hazardous waste
•  Illustrate use of safety
equipment
•  Encourage compliance of
safety regulations
•  List personal protective
equipment
•  Post Material Safety Data
Sheets
•  Location and use of fire
extinguishers
 Lab Material

•  Woven material –
fiberglass, carbon fiber &
aramid
•  Resin fast and slow
•  Vac bagging materials
•  Mixing materials
 Lab
Wet hand lay up Bagging/Debulking
 Composite Inspection Methods
Visual Delamination
 •  VISUAL INSPECTION DEFECTS
DEFECT LAY-UP BAGGING FIBERS RESIN CURE TOOL
SEQUENCE
Bubbles X X X
Wrinkles X X X
Loose Fibers X X
Resin Starved Areas X X X
Resin Rich Areas X X X
Ply Orientation X X X
Porosity X X X
Surface Defects X X X
Inclusions X X X X
Fiber Distortion X X
Voids X X X
Contamination X X X X X
FOD - FOE X X X X X
Burned Resin X X
Burned Bag X
Vacuum Leak X X X X
Delamination X
Ply Gaps X X
TC Problems X X X
Bridging X X X
De-Bonds X X
Damaged Plies X X X
Micro Cracking X X
Matrix (resin) Concerns X
Uncured Resin X X X
Warped Laminate X X
Blown Bag X X
 Course assessments

Testing & Homework

Ply orientations
•  Conventional testing but
with problems that are
specifically applicable to
composite industry
problems.
•  Homework & research
based on composite
industry problems.
IDENTIFY AND NAME THE COMPONENTS INDICATED BELOW
(A THROUGH E)
60.Test Panel or Test Cupon (A)
____________________ B
61. Vacuum Hose
____________________ (B) C

62. Vacuum Probes

____________________ (C)
63.Vacuum Gage
____________________ (D)
64.T.C. Wire
____________________ (E)

D
E
CIRCLE THE CORRECT ANSWER: (example B )
65. The temperature hold period at 240 +/- 100F is intended to:
A. Cure the laminate.
B. Raise the viscosity of the resin so that it will no longer flow.
C. Allow for break time
D. None of the above
66. Preimpregnated cloth may be warmed to provide greater flexibility when laying
up parts.

A. True B. False Page 10

 72. From (Figure 1) below identify item #4.
Nylon bag
#4. __________________________
73. From (Figure 1) below identify item # 1.
Tool Plate
#1. __________________________
74. From (Figure 1) below identify item # 3.
Breather
#3. __________________________
75. From (Figure 1) below identify item # 7.
TC wire
#7. __________________________

(Figure 1) 6 4
5 3
7
Simulated Part 2
flash-breaker tape
1
(1)
(2) Simulated Project Part (use cardboard)
(3)
(4)
(5) Sealant Tape
(6) Vacuum Probe (through the bag)
(7)

© Robert N. Young
Rev. 1/21/06
All Rights Reserved
Page 12
 Team Projects
Projects
•  Develop drawing sets specific
to advanced composite parts
and assemblies
•  Develop a composite product
through design and lay out its
manufacturing sequences and
then cost the product
•  Graded via peer evaluations in
presentation
 References
•  ‘Manufacturing Processes for Advanced Composites’ by F. C. Campbell,
Elsevier
•  ‘Advanced composite stuctures: fabrication and damage repair’ Abaris
Training Resources Inc.
•  ‘Materials Science and Engineering an Introduction’ by William D. Callister,
Jr. 7th ed., Wiley
•  Cessna Training program Bend, OR
•  ‘Mechanics of Composite Materials’ by Autar K. Kaw 2nd Edition CRC Taylor
and Francis Group
•  ‘Materials Selection In Mechanical Design’ by Michael F. Ashby 3rd ed.,
Elsevier
•  CRC Practical Handbook of Materials Selection by James Shackelford,
William Alexander & Jun S. Park
•  Abaris Training-’Advanced Composite Structures: Fabrication and Repair’
•  Cerritos College ‘Composite Lay-Up Manual’