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Weight breakdown
Structure 30%
STRUCTURAL WEIGHT
EVERY ENGINEER SHOULD CONCERN ABOUT WEIGHT OTHERWISE THE COMPANY WILL FIND IT DIFFICULT TO MEET THE COMPETITION TO PRODUCE PLANES WITH GOOD PERFORMANCE A VERY SMALL MARGIN OF WEIGHT DETERMINES THE DIFFERENCE BETWEEN EXCELLENT AND POOR PERFORMANCE OF AIRCRAFT 5% INCREASE IN WEIGHT MAY RENDER A HIGHLY SUCCESSFUL MODEL TOTALLY UNACCEPTABLE WEIGHT OF AIRCRAFT STRUCTURE IS ABOUT 20 TO 40% OF TAKE OFF WEIGHT. ONE 1KG EXCESS WEIGHT IN STRUCTURE OR SYSTEM LEADS TO 10 KG INCREASE IN ALL UP WEIGHT
PRESHABLE & ANISOTROPIC UNITS (PREPREGS) HIGHLY SENSITIVE TO ENVIRONMENT & PROCESS PARAMETERS COMPLEX QC PROCESS
RELATIVELY INSENSITIVE
RELATIVELY SIMPLE QC PROCESS
COMPOSITE MATERIALS
Two or more materials combined on a macroscopic scale to form a useful material Ideal for structural applications where high strength to weight and stiffness-to-weight ratios are required Conventional composites limited to in-plane distributed loads
Matrix
Protect the reinforcement Gives shape to the component Local load transfer Decides the manufacturing process
Classification of Composites
REINFORCEMENT
Particulate
Large Dispersion Particle Strengthened continuous
Fiber
Discontinuous
Unidirectional
Bi-directional
Aligned
Random
TYPES OF COMPOSITES
ADVANCED COMPOSITES
FIBER REINFORCED FIBERS
CARBON KEVELAR GLASS
MATRIX
EPOXY POLYIMIDE POLYESTER
WHY FIBERS?
2500
2000
1500
1000
500
TENSILE STRAIN %
2500
2000
1500
1000
500
COMPRESSIVE STRAIN %
REINFORCEMENT FORMS
UD TAPES
WOVEN FABRICS
All the filaments are oriented in one direction. The tape is fabricated in width ranging from 3 to 60 inches and is supplied in rolls. Unidirectional tape works well when maximum performance is required in one direction. Tapes are made by careful alignment of side-by-side yarns; usually of 1420 or greater denier. Tapes are usually impregnated with resin and are available from many prepreg suppliers.
Unidirectional Weave
Unidirectional Weave Cloth (95% - 0, 5% - 90) This cloth has 95% of its filaments in the warp direction (length direction) and 5% in the fill direction to facilitate material handling. Its strength is approximately equal to unidirectional tape. It is fabricated and available up to 72 inches in width. This weave has the general characteristics: 1) maximum strength in one direction and 2) minimum strength in the transverse direction.
Plain Weave
The oldest and most common basic textile weave in which one warp end (lengthwise thread) weaves over and then under one filling pick (crosswise thread). This weave has the general characteristics: a. Firmest and most stable of the industrial weaves. b. Affords fair porosity with minimum yarn slippage. c. Uniform strength pattern in all surface directions. d. Affords ease of air removal in hand layup or molding.
Basket Weave
This weave is similar to a plain weave, but it has two or more warp ends weaving as one end over and under two or more filling picks weaving as one pick. This weave has the general characteristics: a. Less stable than a plain weave. b. More pliable than a plain weave. c. Flatter and stronger than an equivalent weight and count of plain weave.
OTHER FORMS
POLYMER
THERMOPLASTIC PEEK PPS
THERMOSET
PHENOLIC
EPOXY
POLYIMIDES
Polymer matrix
Thermoset
Epoxy Polyester Phenolics Polyimide
Thermoplastic
PEEK PES
Desired Characteristics of Matrix Resins Mechanical & Thermal High strength High elastic elongation High shear strength High modulus High heat distortion temp. Low creep at use temp. High toughness/impact strength Thermal expansion near fiber Resistance to thermal degradation Low thermal conductivity
Other Factors:
Low cost Low density Low dielectric constant
EPOXY RESINS
GOOD MECHANICAL PROPERTIES UP TO 150 O C SERVICE BONDS TO ALMOST ALL SURFACES
PHENOLIC RESINS
EXCELLENT FIRE RESISTANT LOW SMOKE EMISSION EASY PROCESSING AIRCRAFT INTERIOR COMPONENTS.
BISMALEIMIDE RESINS
EXCELLENT RESISTANCE TO HIGH TEMPERATURE GOOD MECHANICAL PROPERTIES AERO-ENGINE COMPONENTS
ADVANTAGES COMPOSITES
HIGHER SPECIFIC STRENGTH & MODULUS
LIGHT WEIGHT PERFORMANCE FUEL EFFICIENT
TAILARABILITY / ANISOTROPIC
OPTIMUM WEIGHT & PERFORMANCE
EASY MANUFACTURING
COST
- 45%
- 55%
450
250
400
200
Strength MPa
ALUMINIU MALLOY
450
0%
450
170 - 80%
FATIGUE
90
TENSILE
95
COMPOSITE CONSTRUCTION
35%
Assembly
55%
Part Fabrication
50%
CONCERNS
BRITTLENESS
POOR IMPACT PERFORMANCE STRESS CONCENTRATION
PROCESS SENSITIVE
SENSITIVE TO PROCESS PARAMETERS VARIATION / SCATTER
COST
TRANSPORTATION OF PREPREGS
LAMINATED STRUCTURES
LAMINATED STRUCTURE
2O 20%
4O 45%
6O 66%
10O 80%
EFFECT OF SYMMETRY
IMPACT DAMAGE
TOOL DROP WHILE TRANSPORTING & MOVING HAIL STROM RUNWAY DEBRIS
DELAMINATION
DELAMINATION
APPLICATIONS OF PREPREGS
CURE PARAMETERS
DE BULKING
Large quantities of air are inevitably trapped between each prepreg layer and can be removed by covering the prepreg with a release film, a breather layer and applying a vacuum bag. The vacuum should be applied for 10-15 minutes at Room Temperature. The first ply attached to the tool face is generally debulking and this can be repeated after every 3 or 5 layers depending on the prepreg thickness and component shape. Debulking can be carried out overnight or during a natural break in the lay-up process.
Temperature
The oven/autoclave, component and tooling, should all reach and remain above the minimum cure temperature throughout the cure cycle. Thermocouples used to monitor the temperature should be placed carefully to ensure accurate information is received for the whole system and to operate at the cure temperature 5 C.
Cure time
Each prepreg has a recommended cure time which starts when the lowest thermocouple reading reaches the minimum cure temperature. Extended cure times at the recommended cure temperature do not normally have an adverse effect on the component quality.
Heat up rate
The matrix, viscosity, flow, reaction rates and component surface quality are all effected by the chosen heat up rates.
Generally, fast heating rates are possible for thin components and slow heating rates are used for large and thick components.
The heat up rate selected should avoid large temperature differentials between the component and the heat source.
Cooling rates
Cooling cycles should be controlled to avoid a sudden Temperature drop which may induce high thermal stresses in the component.
Pressure and/or vacuum should be maintained throughout the cooling period.
Vacuum
Used to remove air from the prepreg lay-up and provide a consolidating pressure for oven curing. It is common practice in autoclave cure cycles to reduce the applied vacuum to a low level.
PRESSURE
CONSOLIDATION OF LAYERS
DELAMINATION
FRACTURE
VOIDS
EDGE DELAMINATION
MONOLITHIC
CO CURED BONDED COBONDED
SANDWICH
CO CURED BONDED COBONDED
BONDING
SANDWICH STRUCTURES
VERY EFFICIENT IN RESISTING BENDING LOADS LIGHT IN WEIGHT LIMITED BY SHEAR DEFORMATION
DELAMINATION
CORE CRUSH
MOISTURE
BONDING FIXTURE
HEALTH ISSUES
SKIN CONTACT
CURED RESIN UNCURED RESIN & HARDENER FIBERS SOLVENTS (ACETONE & MEK)
INHALATION
HARDENER DUSTS (DRILLING& TRIMMING)
PREVENTION OF EXPOSURE
IMPORTANCE OF GLOVES
Prepregs can be difficult to handle with gloves, but don't give in to the urge to work bare-handed. Although the focus of this discussion has been on contact hazards, adequate ventilation should also be provided to minimize respiratory risks.
THANK YOU
Unidirectional Tape Prepreg All the filaments are oriented in one direction. The tape is fabricated in width ranging from 3 to 60 inches and is supplied in rolls. Unidirectional tape works well when maximum performance is required in one direction. Tapes are made by careful alignment of side-by-side yarns; usually of 1420 or greater denier. Tapes are usually impregnated with resin and are available from many prepreg suppliers.
Unidirectional Weave Cloth Prepreg (95% - 0, 5% - 90) This cloth has 95% of its filaments in the warp direction (length direction) and 5% in the fill direction to facilitate material handling. Its strength is approximately equal to unidirectional tape. It is fabricated and available up to 72 inches in width.
A greater number of relatively strong warp yarns and fewer, and generally weaker, filling yarns give this type of reinforcing fabric maximum strength in the warp direction only. This weave has the general characteristics: 1) maximum strength in one direction and 2) minimum strength in the transverse direction.
Bidirectional Weave Cloth Prepreg This cloth has close-to-equal proportions of filaments in the warp direction (length) and fill direction (width). Note that in satin weaves, the warp filaments are predominantly on one side and the fill is predominantly on the other. Hence, the cloth is not thermally balanced within itself and in thin laminates it may be necessary to specify on which side of the cloth the warp should be to prevent twisting of the laminates after curing. The cloth is fabricated in widths up to 72 inches.
S/N 1 2 3 4 5 6 7
DESCRIPTION CARBON PRE-PREG CARBON PRE-PREG CARBON PRE-PREG CARBON UD TAPE CARBON PRE-PREG GLASS PRE-PREG GLASS PRE-PREG
DESIGNATION 913-40%-G801-1020 913-40%-G802 NT1000 913-40%-G815-1070 NCHR 913-35%-132T300 913-40%-G833-1000 913-37%-120-1270 913-37%-7781-1270
S/N 8 9 10 11 12 13 14
913 G-20982-34+/R-GLASS PRE-PREG 3%-W 1200 R-GLASS UD TAPE SINGLE TOW 913 G-R-7-33%-W 300 MM MR 913-28%-1XR1600
S/N 15 16 17 18 19
DESCRIPTION GLASS UD GLASS SINGLE TOW KEVLAR PREPREG GLASS PRE-PREG GLASS PRE-PREG
DESIGNATION NVE 913-28%-192-EC 9756 ME 913-28%-1XEC 9756 914 K-285-50+/-3.0%-W 1200 MM 914 G-120-45+/-5.0%-W 1270 MM 914 G-7781-37+/-3.0%-W 1270 MM
20
21
FM 73
FM 490A