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Book Chapter
Thermoset Composite Fabrication Processes
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870119
EISBN: 978-1-62708-314-0
... part on its individual tool. 5.2.3 Roll or Tape Wrapping Small-diameter, hollow cylindrical parts, such as golf club shafts and fishing rods, are made by a process called roll wrapping . Rectangular or triangular prepreg plies, called flags , are cut and then roll wrapped at various angles...
Abstract
This chapter familiarizes readers with the many and varied thermoset composite fabrication processes and the types of applications for which they were developed. It describes wet lay-up, prepreg lay-up, and low-temperature vacuum bag curing prepreg processes, which are best suited for low-volume, medium-sized and larger parts. It also discusses filament winding and preforming processes (including weaving, knitting, stitching, and braiding) in addition to resin-transfer molding, resin film infusion, and pultrusion.
Book Chapter
Fibers and Reinforcements
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870031
EISBN: 978-1-62708-314-0
..., such as twisting, weaving, knitting, carding, and felting. Yarns and rovings are used in filament winding, prepreg tape, and pultrusion processes. Applications include missile cases, pressure vessels, sporting goods, cables, and tension members. Aramid paper used in honeycomb sandwich constructions is made...
Abstract
This chapter discusses the properties and processing characteristics of glass, aramid, carbon, and ultra-high molecular weight polyethylene fibers and related product forms, including woven fabrics, prepreg, and reinforced mats. It also includes a review of fiber terminology as well as physical and mechanical property data for commercially important high-strength fibers.
Book Chapter
Design and Certification Considerations
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870489
EISBN: 978-1-62708-314-0
... (b) (a) Depends on how “highest performance” is defined—high temperature, toughness, and superior mechanical properties. (b) Material form is not driven by performance, but is typically defined by the manufacturing process. Relative comparison of dry fiber/neat resin and prepreg...
Abstract
This chapter discusses design and certification considerations, including materials and process selection, the building block approach to certification, design allowables, and design guidelines. It also includes information on damage tolerance and environmental sensitivity.
Book Chapter
Introduction—Composite Materials and Optical Microscopy
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.omfrc.t53030001
EISBN: 978-1-62708-349-2
... Abstract This chapter provides a general description of materials and methods for manufacturing high-performance composites. The materials covered are polymer matrices and prepreg materials and the methods include infusion processes, composite-toughening methods, matrix-toughening methods...
Abstract
This chapter provides a general description of materials and methods for manufacturing high-performance composites. The materials covered are polymer matrices and prepreg materials and the methods include infusion processes, composite-toughening methods, matrix-toughening methods, and dispersed-phase toughening. In addition, the chapter provides information on interlayer-toughened composites and honeycomb or foam structure composite materials. It also discusses the processes in optical microscopy of composite materials.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.omfrc.9781627083492
EISBN: 978-1-62708-349-2
Book Chapter
Thermoplastic Composite Fabrication Processes
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870183
EISBN: 978-1-62708-314-0
... of the product form used. For example, well-consolidated hot melt–impregnated tape can be successfully consolidated in very short times (minutes if not seconds), while woven powder coated or comingled prepregs require longer times for the resin to flow and impregnate the fibers. Occasionally, a process called...
Abstract
This chapter discusses thermoplastic composite fabrication processes and related equipment and procedures. The discussion covers consolidation and thermoforming operations as well as joining methods.
Book Chapter
Polymer-Matrix Composites
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 October 2012
DOI: 10.31399/asm.tb.lmub.t53550385
EISBN: 978-1-62708-307-2
..., knitting, carding, and felting. Yarns and rovings are used in the filament winding, prepreg tape, and pultrusion processes. Applications include missile cases, pressure vessels, sporting goods, cables, and tension members. Although continuous filament forms dominate composite applications, discontinuous...
Abstract
Polymer-matrix composites are among the lightest structural materials in use today. They are also highly resistant to corrosion and fatigue and their load-carrying capabilities, such as strength and stiffness, can be tailored for specific applications. This chapter discusses the primary advantages and disadvantages of polymer-matrix composites, how they are produced, and how they perform in different applications. It describes the construction of laminates, the fibers and resins used, and the methods by which they are combined. It explains how strength, modulus, toughness, and high-temperature and corrosion behaviors are determined by the orientation, shape, and spacing of fibers, the number of plies, resin properties, and consolidation and forming methods. The chapter also covers secondary fabrication processes, such as thermoforming, machining, and joining, as well as production equipment and product forms, and include guidelines for optimizing tradeoffs when selecting fibers, resins, and production techniques.
Book Chapter
Void Analysis of Composite Materials
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.omfrc.t53030147
EISBN: 978-1-62708-349-2
... systems ( Ref 6 , 9 ). In addition to water, solvents may be used in the formulation stage or during the processing of prepreg materials ( Fig. 8.1 ) ( Ref 10 ). These volatile materials are difficult to completely remove and, in many cases, cause voids in the cured parts. Fig. 8.1 Glass fabric...
Abstract
Achieving the best-performing composite part requires that the processing method and cure cycle create high-quality, low-void-content structures. If voids are present, the performance of the composite will be significantly reduced. There are multiple causes of voids in composite materials; they are generally categorized as voids that are due to volatiles (such as solvents, water) or voids that result from entrapped air. This chapter describes the analysis of various types of voids. It reviews techniques for analysis of voids at ply-drops, voids due to high fiber packing, and voids that occur in honeycomb core composites. The final section of the chapter discusses void documentation through the use of nondestructive inspection techniques and density/specific gravity measurement methods.
Book Chapter
Surface Analysis
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2003
DOI: 10.31399/asm.tb.cfap.t69780383
EISBN: 978-1-62708-281-5
... in the manufacturing process, are often concentrated at surfaces and interfaces. Thus, even minute differences in the bulk can be magnified and detected easily at the surface. Similarly, environmental degradation often has its most pronounced effects at surfaces. The workhorse instrument in surface analysis...
Abstract
This article covers common techniques for surface characterization, including the modern scanning electron microscopy and methods for the chemical characterization of surfaces by Auger electron spectroscopy, X-ray photoelectron spectroscopy, and time-of-flight secondary ion mass spectrometry. The principles of surface analysis and some of the applications of the technique in polymer failure studies are also provided.
Book Chapter
Glossary of Filament-Winding Terms
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 September 2011
DOI: 10.31399/asm.tb.cfw.t52860151
EISBN: 978-1-62708-338-6
... has 140,000 filaments. strand. An assembly of continuous filaments, towpreg. Preimpregnated tow or strands for fil- without twist. When used as a unit, may ament winding. It differs from typical prepreg include tows, ends, yarn, and denier. tape in that the tow is wound onto the rov- stress...
Abstract
This appendix is a compilation of terms and definitions related to composite filament winding.
Book Chapter
Processing Science of Polymer Matrix Composites
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870201
EISBN: 978-1-62708-314-0
... surfaces mated, sealed off, and did not allow air evacuation; air became trapped in the laminate, resulting in porosity. To circumvent this problem while maintaining the quality advantages of the resin filming process, the manufacturers deliberately began only partially impregnating the prepreg. It should...
Abstract
This chapter provides an overview of the tools and techniques, as well as some of the underlying theory, that have proven useful for process modeling and simulation. It begins by presenting the framework of a thermoset cure model that accounts for kinetics, viscosity, heat transfer, flow, voids, and residual stress. It then discusses each variable in detail, explaining how it affects the cure process, how it is measured, and how it can be expressed mathematically in the form of a simple model. The discussions throughout the chapter are supported by numerous images, diagrams, and data plots.
Book Chapter
Matrix Resin Systems
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870063
EISBN: 978-1-62708-314-0
... cure cycles, and higher pressures (such as 200 psig). Volatiles and voids are always potential problems when processing polyimides. Even the so-called addition-curing systems can exhibit volatile problems as the low molecular weight monomers are usually dissolved in solvents during manufacturing...
Abstract
This chapter discusses the use of thermoset and thermoplastic resins in polymer matrix composites. It begins by explaining how the two classes of polymer differ and how it impacts their use as matrix materials. It then goes on to describe the characteristics of polyester, vinyl ester, epoxy, bismaleimide, cyanate ester, polyimide, and phenolic resins and various toughening methods. The chapter also covers thermoplastic matrix materials and product forms and provides an introduction to the physiochemical tests used to characterize resins and cured laminates.
Book Chapter
Repair
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870517
EISBN: 978-1-62708-314-0
... concern with wet lay-up patches is that it may be difficult or impossible to match the strength and stiffness of the original structure if the structure is thin and made from unidirectional tape, since the wet lay-up material will be woven cloth. Both prepreg and wet lay-up patches have the advantage...
Abstract
This chapter discusses the primary methods used to repair composites, including fill repairs, injection repairs, bolted repairs, and bonded repairs. It also discusses issues associated with field repairs.
Book Chapter
Programming Techniques, Computer-Aided Manufacturing, and Simulation Software
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 September 2011
DOI: 10.31399/asm.tb.cfw.t52860035
EISBN: 978-1-62708-338-6
... of programming various geometries using advanced software tools and discusses how various materials, such as rovings, tow-preg, prepreg tape, and woven materials, affect winding program generation. computer numerical controlled winding machines computer-aided manufacturing filament winding prepreg tape...
Abstract
This chapter discusses the ways in which the evolution of filament winding software systems has capitalized on the inherent flexibility of computer numerical controlled winding machines and enhanced their productivity. It provides a detailed discussion on different types of geometries that can be wound, from the simple to the highly complex, with insight into the limitations, advantages, and challenges of each. Components covered include classic axisymmetric parts (rings, pipes, driveshafts, pipe reducers, tapered shafts, closed-end pressure vessels, and storage tanks), nonround sections (aeromasts, airfoils, box sections, and fuselage sections), curved-axis parts (elbows, ducts), and special applications (tees). Basic winding concepts, such as band pattern, are discussed and explained, and some simple predictive formulae are introduced. The chapter also provides examples of programming various geometries using advanced software tools and discusses how various materials, such as rovings, tow-preg, prepreg tape, and woven materials, affect winding program generation.
Book
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2011
DOI: 10.31399/asm.tb.cfw.9781627083386
EISBN: 978-1-62708-338-6
Book Chapter
Composite Mechanical Properties
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870373
EISBN: 978-1-62708-314-0
... conventional textile operations, such as twisting, weaving, knitting, carding, and felting. Yarns and rovings are used in filament-winding, prepreg tape, and pultrusion processes. Applications include missile cases, pressure vessels, sporting goods, cables, and tension members. Although continuous-filament...
Abstract
This chapter examines the static, fatigue, and damage tolerance properties of glass, aramid, and carbon fiber systems. It also explains how delaminations, voids, porosity, fiber distortion, and fastener hole defects affect impact resistance and strength.
Book Chapter
Static Mechanical Tests for Filament-Wound Composites
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 September 2011
DOI: 10.31399/asm.tb.cfw.t52860095
EISBN: 978-1-62708-338-6
... that parallel the configurations of the laminate layup. These are the test specimens that support confidence in the filament winding manufacturing process. Usually, it is not possible to provide A- or B-basis allowables so that the filament-wound structure can be confidently designed. There are data...
Abstract
The objective of mechanical testing of an engineered material is to provide data necessary for the analysis, design, and fabrication of structural components using the material. The testing of filament-wound composite materials offers unique challenges because of the special characteristics of composites. This chapter describes suitable static mechanical test techniques for characterizing laminated composite materials. The approach is to provide recommended techniques, based on consensus opinions of fabricators and users of filament-wound composites, and to survey available techniques that have been used successfully in the field. The chapter describes the effects of various factors on the properties of composite constituents, including fibers, resins, and unidirectional plies. Some aspects of specimen selection are also described. The chapter provides information on pressure bottles and tubular parts that have been developed as standard test specimens for combined load testing of composites.
Book Chapter
Ceramic Matrix Composites
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870573
EISBN: 978-1-62708-314-0
... temperatures. Nippon’s Nicalon series of SiC fibers are the most prevalent. Nicalon fibers are produced by a polymer pyrolysis process that results in a structure of ultrafine β -SiC particles approximately 1 to 2 nm dispersed in a matrix of amorphous silicon oxide and free carbon. Fiber manufacture consists...
Abstract
This chapter discusses the types of fibers and matrix materials used in ceramic matrix composites and the role of interfacial coatings. It describes the methods used to produce ceramic composites, including powder processing, slurry infiltration and consolidation, polymer infiltration and pyrolysis, chemical vapor infiltration, directed metal oxidation, and liquid silicon infiltration.
Book Chapter
Metal Matrix Composites
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870537
EISBN: 978-1-62708-314-0
... components. However, since many of the processing procedures originally developed for aluminum MMCs have been transitioned to titanium, a brief review of these methods will be given. Fig. 20.16 Boron monofilament manufacture. BCl 3 , boron trichloride Fig. 20.17 Boron monofilament reactor...
Abstract
This chapter discusses the advantages and disadvantages of metal matrix composites and the methods used to produce them. It begins with a review of the composition and properties of aluminum matrix composites. It then describes discontinuous composite processing methods, including stir and slurry casting, liquid metal infiltration, spray deposition, powder metallurgy, extrusion, hot rolling, and forging. The chapter also provides information on continuous-fiber aluminum and titanium composites as well as particle-reinforced titanium and fiber metal (glass aluminum) laminates.
Book Chapter
Nondestructive Inspection
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.scm.t52870333
EISBN: 978-1-62708-314-0
... along with best practices and procedures. composite manufacturing radiographic inspection thermographic inspection ultrasonic inspection visual inspection FLAWS CAN OCCUR, unfortunately, at almost any stage of the composite manufacturing process or during service. A summary of some...
Abstract
This chapter discusses the use of nondestructive inspection methods, including visual, ultrasonic, radiographic, and thermographic techniques, and the types of flaws and damages they can reveal in composite parts and assemblies. It describes the basic principles behind each method along with best practices and procedures.
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