PROJECT ON COMPOSITE MATERIALS FOR AEROSPACE APPLICATIONS

PROJECT DETAILS:

TOPICS COVERED IN THIS PROJECT ARE:

1) INTRODUCTION OF COMPOSITE MATERIALS 2) COMPOSITE MATERIALS 3) SELECTION OF MATERIALS

4) FABRICATION TECHNIQUES
5) EXPERIMENTAL WORK 6) NON DESTRUCTIVE TESTS 7) DESTRUCTIVE TESTS 8) RESULTS AND DISCUSSION 9) CONCLUSION

INTRODUCTION:
Heat resistant composites are essential for the successful launch and operation of all space vehicles. The selection of a composite material depends upon the mission of the space craft. While often the temperature capability is a major concern, the goal remains to protect the internal components at a minimal weight. This means extra insulation if the exterior material has a high heat capacity. In order to meet the mission objectives and the criteria the heat resistant material essential properties are it should have high heat of ablation, specific heat and low thermal conductivity, expansion coefficient, erosion rate. Fiber reinforced polymer matrix composite materials has constituted a major breakthrough in the construction of lightweight structures. In particular significant benefits have been realized in the aerospace sector to meet the severe performance requirements with stringent demands of reliability. Almost all aerospace structural components airframes of fighter aircraft, helicopters, control surface and fins of civil aircraft, various planes in satellites, antennas, rocket motor casings and some complete airframes of small aircraft are witnessing an increasing use of the advanced composites.

Aerospace applications:
Use of composites in LIGHT COMBAT AEROPLANE (LCA )Tejas:

Fig :1

Use of composites in LCH

Fig :2 Light Combat Helicopter

Helicopter Blade:

Fig :3 Helicopter blade

COMPOSITE MATERIALS:
A composite material can be defined as a macroscopic combination of two or more distinct materials, having a recognizable interface between them. However, because composites are usually used for their structural properties, the definition can be restricted to include only those materials that contain reinforcement (such as fibres or particles) supported by a binder (matrix) material. Composite materials generally consist of a bulk material, called matrix, and a filler of some type, viz., fibres, whiskers, or particles. Composite materials are usually divided into three broad groups identified by the matrix material: viz., polymer matrix composite (PMC), metal matrix composite (MMC) and ceramic matrix composite (CMC). These composite can have fibres, whiskers, or particulates in a matrix forming a single thin lamina, or a laminated composite consisting of layers of various laminae. The fibres, whiskers, or particulates are usually the material that carries the major stresses and loads, while the matrix holds them together to facilitate the transfer of stresses to the fibres/whiskers/particulates. It can be defined as a heterogeneous solid structural material consisting of two or more distinct components that are mechanically or metallurgically bonded together such as wire or filament of high melting substance embedded in a metal or non

Classification of composites:
Composite materials are classified based on the matrix materials as well as the reinforcements as follows. A) Based on the Matrix material

B) Based on the Reinforcement

Types of fibres:
Advanced Fibres:
Fibres possessing high specific stiffness [E/] and specific strength [/]) a) Glass b) Carbon c) Organic d) Ceramic

Natural Fibres:

a) Animal fibres i) Silk ii)Wool iii) Spider silk iv) Sinew v) Camel hair b) Vegetable fibres i) Cotton ii) Jute iii) Bamboo iv) Sisal v) Maze vi) Hemp vii) Sugarcane viii) Banana ix) Ramie x) Kapok xi) Coir xii) Abaca xiii) Kenaf xiv) Flax xv) Raffia palm..

 Mineral fibres :
i) Asbestos iii) Mineral wool
Advanced Fibres:

ii) Basalt iv) Glass wool

Glass fibres: Ancient Egyptians made containers from coarse fibres drawn from heat softened glass. Produced by extruding molten glass at 1200C Passed through spinnerets of 1-2 mm diameter Then drawing the filaments to produce fibres of diameter between 1-5 m Individual filament is small in diameter, isotropic in behavior and very flexible

variety of forms:
E glass: high strength and high resistivity S2 glass: high strength, modulus and stability under extreme temperature, corrosive environment R glass: enhanced mechanical properties C glass: resists corrosion in an acid environment D glass: dielectric properties In general, glass fibres are isotropic in nature

In the figure 4 given below the elements with which the fibres are made is shown by the rounded up oval. They are used for advanced fibre reinforcements for the composites.

PERIODIC TABLE

Carbon fibres:
carbon- carbon covalent bond is the strongest in nature

Thomas Edison made carbon fibre from bamboo when experimenting for light bulb Carbon fibre contains 80-95 % of carbon and graphite fibre contains more than 99% carbon Carbon fibre is produced at 1300C while graphite fibre is produced in excess of 1900C

 Precursor fiber is carbonized rather then melting

Filaments are made by controlled pyrolysis (chemical deposition by heat) of a precursor material in fiber form by heat treatment at temperature 10003000 C

Different fibers have different morphology, origin, size and shape. The morphology is very dependent on the manufacturing process. The size of individual filament ranges from 3 to 14 m. Hence, very flexible. Maximum temperature of use of the fibers ranges from 250 C to 2000 C. Properties changes with temperature at higher temperature. The maximum temperature of use of a composite is controlled by the use temperature of the matrix Thus, carbon fibers are anisotropic in nature polyamide family of nylons.

Aramid fibres:
Aromatic

Filament diameter about 12 m and partially flexible High tensile strength Very low elongation up to breaking point Significantly lower strength in compression

ARAMID FIBRES

Types of Matrix materials:

Polymers:
a) Thermoplastic: Soften upon heating and can be reshaped with heat & pressure b) Thermosetting: become cross linked during fabrication & do not soften upon reheating

c) Metals:
d) Ceramics: e) Carbon and Graphite: Thermoplastics:

polypropylene,
polyvinyl chloride (PVC), nylon, polyurethane,

poly-ether-ether ketone (PEEK),

polyphenylene sulfide (PPS), polysulpone

 higher toughness

high volume low- cost processing Temperature range 225C

Thermoplastics:
Thermoplastics are increasingly used over thermosets becuase of the following reasons:

Processing is faster than thermoset composites since no curing reaction is required. Thermoplastic composites require only heating, shaping and cooling.

Better properties:

high toughness (delamination resistance) and damage tolerance

low moisture absorption chemical resistance They have low toxity.

Thermosets:

polyesters, epoxies, polyimides Other resins

Polyesters:

Low cost Good mechanical strength Low viscosity and versatility Good electrical properties Good heat resistance Cold and hot molding Curing temperature is 120C

Epoxy:

Epoxy resins are widely used for most advanced composites.

Advantages:

Low shrinkage during curing High strength and flexibility Adjustable curing range Better adhesion between fibre and matrix

Better electrical properties

Resistance to chemicals and solvents

Disadvantages:

somewhat toxic in nature

limited temperature application range upto 175C

moisture absorption affecting dimensional properties high thermal coefficient of expansion slow curing

Polyimides:

Excellent mechanical strength Excellent strength retention for long term in 260-315C (500-600F) range

Excellent electrical properties Good fire resistance and low smoke emission

Hot molding under pressure and

Curing temperature is 175C (350F) and 315C

Problems with using polymer matrix materials:

Limited temperature range Susceptibility to environmental degradation due to moisture, radiation, atomic oxygen (in space) Low transverse strength High residual stress due to large mismatch in coefficients of thermal expansion both fiber and matrix Polymer matrix can not be used near or above the glass transition temperature

Metals:

Aluminum Titanium Copper

Higher use temperature range Aluminum matrix composite use temperature range above 300C and titanium at 800 C Higher transfer strength, toughness( in contrast with brittle behavior of polymers and ceramics) The absence of moisture & high thermal conductivity (copper)

Disadvantages:

Heavier More susceptible to interface degradation at the fiber/matrix interface and to corrosion

Ceramics:
(a) Carbon, (b) Silicon carbide and (c) Silicon nitride Ceramic have use very high temperature range > 2000 C High elastic modulus Low density

Disadvantages:

brittleness Susceptible to flows

Carbon:
carbon fibres in carbon matrix carbon/carbon composites used under extreme mechanical and thermal loads (space applications)

Advantages:

Low specific weight

High heat absorption capacity Resistance to thermal shock High resistance to damage

Exceptional frictional properties at high energy levels

Resistance to high temperatures Chemical inertness low coefficient of thermal expansion (excellent dimensional stability)

Disadvantages:

low resistance to oxidation above 500C high cost of materials and manufacturing

FABRICATION TECHNIQUES:
Manufacturing techniques for composites are not dependent on the type of matrix material. In fact, some metal forming techniques have been adapted to composites fabrication (e.g., matched-metal die molding). However, processing conditions are entirely dependent on the type of matrix material

used. For instance, thermosets require long processing times, whereas

thermoplastics require relatively high pressures and temperatures.

1.1 FABRICATION OF FIBROUS COMPOSITES:

There are more than 50 processes depending upon fibre and matrix material type and nature. Some of them are illustrated below.

Wet/Hand Lay-Up Spray Lay-Up Vacuum Bagging Filament Winding Pultrusion Resin Transfer Molding (RTM) Pre-pregg

Resin Film Infussion

1.1.1WET/HAND LAY-UP:
Description Resins are impregnated by hand into fibres which are in the form of woven, knitted, stitched or bonded fabrics. This is usually accomplished by rollers or brushes, with an increasing use of niproller type impregnators for forcing resin into the fabrics by means of rotating rollers and a bath of resin. Laminates are left to cure under standard atmospheric conditions.

1.1.2SPRAY LAY-UP:
Description Fibre is chopped in a hand-held gun and fed into a spray of catalysed resin directed at the mould. The deposited materials are left to cure under standard atmospheric conditions.

1.1.3VACUUM BAGGING:
Description This is basically an extension of the wet lay-up process described above where pressure is applied to the laminate once laid-up in order to improve its consolidation. This is achieved by sealing a plastic film over the wet laid-up laminate and onto the tool. The air under the bag is extracted by a vacuum pump and thus up to one atmosphere of pressure can be applied to the laminate to consolidate it .

1.1.4FILAMENT WINDING:
Description This process is primarily used for hollow, generally circular or oval sectioned components, such as pipes and tanks. Fibre tows are passed through a resin bath before being wound onto a mandrel in a variety of orientations, controlled by the fibre feeding mechanism, and rate of rotation of the mandrel.

1.1.5PULTRUSION:
Description Fibres are pulled from a creel through a resin bath and then on through a heated die. The die completes the impregnation of the fibre, controls the resin content and cures the material into its final shape as it passes through the die. This cured profile is then automatically cut to length. Fabrics may also be introduced into the die to provide fibre direction other than at 0. Although pultrusion is a continuous process, producing a profile of constant cross-section, a variant known as pulforming allows for some variation to be introduced into the crosssection. The process pulls the materials through the die for impregnation, and then clamps them in a mould for curing. This makes the process non-continuous, but accommodating of small changes in cross-section.

1.1.6RESIN TRANSFER MOLDING (RTM) :

Description Fabrics are laid up as a dry stack of materials. These fabrics are sometimes pre-pressed to the mould shape, and held together by a binder. These preforms are then more easily laid into the mould tool. A second mould tool is then clamped over the first, and resin is injected into the cavity. Vacuum can also be applied to the mould cavity to assist resin in being drawn into the fabrics. This is known as Vacuum Assisted Resin Injection (VARI). Once all the fabric is wet out, the resin inlets are closed, and the laminate is allowed to cure. Both injection and cure can take place at either ambient or elevated temperature.

1.1.7Pre-Pregg:
Description Fabrics and fibres are pre-impregnated by the materials manufacturer, under heat and pressure or with solvent, with a pre-catalysed resin. The catalyst is largely latent at ambient temperatures giving the materials several weeks, or sometimes months, of useful life when defrosted. However to prolong storage life the materials are stored frozen. The resin is usually a near-solid at ambient temperatures, and so the preimpregnated materials (prepregs) have a light sticky feel to them, such as that of adhesive tape. Unidirectional materials take fibre direct from a creel, and are held together by the resin alone. The prepregs are laid up by hand or machine onto a mould surface, vacuum bagged and then heated to typically 120-180C.

1.1.8RESIN FILM INFUSION:

Description

Dry fabrics are laid up interleaved with layers of semi-solid resin film supplied on a release paper. The lay-up is vacuum bagged to remove air through the dry fabrics, and then heated to allow the resin to first melt and flow into the air-free fabrics, and then after a certain time, to cure.

1.2 Selection Of The Fabrication Process:

Several factors should be considered before selecting the manufacturing process for a particular part;

User requirements Performance requirements Total production volume Production rate Cost of production Size of the production Surface finish of the final product

Geometry of the product

Material These are important for all manufacturing processes, and even more so for composite materials Ideally, structural design of the product, and design of the required manufacturing process should be completed using a concurrent approach.

EXPERIMENTAL WORK:
EXPERIMENTAL WORK In this project the matrix is conventional phenolic resin and it is modified with Di-amine and ether. By this modification it is observed that when phenolic resin is modified with Di- amine the gel time is increased. And point of trouble is decreased considerably. Similar changes are observed in the properties of the resin by modifying with ether. In this experimental work the following types of laminates were made: E-Glass (V-9)/Phenolic composite E-Glass (V-9)/Di-amine modified phenolic composite E-Glass (V-9)/ether modified phenolic composite Rayon carbon/ether modified Phenolic composite Rayon carbon/Di-amine modified Phenolic composite

Preparation of laminate by Hand Lay-Up Process:

Even though the method has been replaced with automated techniques, the lay-up of pre impregnated material by hand is the oldest and most common fabrication method for advanced composite structures. Furthermore, the basic features of the method remain unchanged. each step in the hand lay-up of a flat composite laminate is shown in different steps. Each step must follow in successive fashion in order to obtain a highquality composite laminate after final processing. A description of these steps follows.

Step 1:The surface of the tool is cleaned and a release agent is applied. If the surface is not clean, then the release agent will not function properly. The release agent can be in liquid form, or it may be a solid film. Step2:An optional sacrificial layer is laid up on the tool surface. This layer is usually a fiberglass fabric made with the same resin system as the composite laminate. The sacrificial layer protects the laminate from surface abrasion and surface irregularities during manufacturing. Step3:Figure 5.2. A peel ply is placed on top of the sacrificial layer. The peel ply will be removed after processing.

AUTOCLAVE CURING:

The best quality parts are cured using an autoclave. Autoclaves have been used extensively for processing high-performance composite materials in the civilian and military aerospace industries. An autoclave consists of a large cylindrical metal pressure vessel with end enclosures that is thermally insulated and heated. Most autoclaves have a forcedhot-gas circulation system as well. An autoclave is pressurized using air or an inert gas such as nitrogen. It has the ability to cure parts using large, hydrostatic like pressure. A typical autoclave can pressurize up to 20 atm. A circulating fan forces the hot gases through a series of baffles within the autoclave in a circulation loop that runs the length of the autoclave. Typically, this fan is housed at one end of the autoclave and the interior gases are drawn from the central portion of the cylinder, through the baffles, and they return to the other end through a jacket that covers the interior wall. The autoclave applies a pressure to the outer surface of the composite part through pressurization of the interior gases. This pressure is then transferred through the tool plate(s), breather plies, bleeder plies, and other secondary materials to the laminate surface. From there the pressure is shared between the fiber and matrix during curing. The most important aspect is the matrix resin pressure during cure. If it is too low, then voids can grow in the resin or inadequate resin bleeding may occur. In general, composite structures which have been processed in an autoclave exhibit uniform thicknesses, good consolidation, and very low void content.

TOPICS TO BE COVERED:

(A)

MACHINING OF LAMINATES

(B)

NON DESTRUCTIVE TESTING OF LAMINATE

(C)

DESTRUCTIVE TESTING

(D)

RESULTS AND DISCUSSION

(E)

CONCLUSION

MACHINING OF LAMINATES:

Thank you