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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.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2011
DOI: 10.31399/asm.tb.cfw.t52860001
EISBN: 978-1-62708-338-6
...) ( Ref 1.3 ), but there is no comparable database for filament-wound composites that use prepreg tow and wet resin-impregnated tow or roving. The principles of composite analysis and “B”-basis allowables are discussed more extensively in Chapters 8 and 7 , respectively. Structural Analysis...
Abstract
Most filament winding machines now have computer controls and at least three axes. Winding with four axes is increasingly common because the shapes of the products have evolved to include more complexity. The automation used on the winding machine and ancillary components does not eliminate the need for proper fiber handling. This chapter is a primer on modern filament winding equipment and its use, starting with an overview of machine control and then discussing the design and structural analysis of filament wound components such as pressure vessels, pipes, grid structures, deep sea oil platform drill risers, high-speed rotors, and filament-wound preforms.
Book Chapter
Specifications and Designations of Fibers and Resins
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 September 2011
DOI: 10.31399/asm.tb.cfw.t52860149
EISBN: 978-1-62708-338-6
... 463 750 yield E-glass fiber tow Owens Corning M40J Carbon/graphite Toray T 1000G Highest-strength carbon/graphite Toray T-300 High-strength carbon/graphite Toray T-700 Carbon/graphite Toray T-800 Carbon/graphite Toray S2 glass High-strength glass tow AGY Zylon HM...
Abstract
This appendix lists the designations, commercial sources, and suppliers of different types of fibers and resins.
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
... Fiber placement, shown conceptually in Fig. 5.9 , is a hybrid between filament winding and tape laying. A fiber placement, or tow placement, machine allows individual tows of prepreg to be placed by the head. The tension on the individual tows normally ranges from zero up to about 2 lb (0.9 kg...
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
... product form in which a large number of parallel filaments (such as tows) are held together with an organic matrix material (such as epoxy) commonly referred to as prepreg (preimpregnated with resin). The length of the tape in the direction of the fibers is much greater than the width, and the width...
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
Toughening Methods for Thermoset-Matrix Composites
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.omfrc.t53030177
EISBN: 978-1-62708-349-2
... involves filming a particle-modified resin and relying on the particles to filter out on the fiber tow surfaces or prepreg surface during the prepregging process ( Ref 23 ). Figure 10.6 shows preformed particles in the interlayer region of a composite material that was developed using single-pass...
Abstract
The second-generation composite materials were added to increase the strain to failure of the primary phase and/or create a dispersed second phase, thereby enhancing the fracture toughness of the thermosetting matrix. These matrices offered novel design capabilities for composites in a variety of aircraft applications. To improve the damage tolerance of composite materials even further, an engineering approach to toughening was used to modify the highly stressed interlayer with either a tougher material or through the use of preformed particles, leading to the third generation of composite materials. This chapter discusses the development, processes, application, advantages, and disadvantages of dispersed-phase toughening of thermoset matrices. Information on the processes of particle interlayer toughening of composite materials is also included.
Book Chapter
Special Sample Preparation and Polishing
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.omfrc.t53030067
EISBN: 978-1-62708-349-2
... fabric prepreg provides information about the degree of impregnation, the resin and fiber distribution, and commingling of adjacent fiber tows ( Ref 2 , 3 ). This information can be used to understand and identify the effects of different prepreg processing parameters on the cured microstructure...
Abstract
The most common methods for preparing polymeric composites for microscopic analysis can be used for most fiber-reinforced composite materials. There are, however, a few composite materials that require special preparation techniques. This chapter discusses the processes involved in the preparation of titanium honeycomb composites, boron fiber composites, titanium/polymeric composite hybrids, and uncured prepreg materials.
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
..., and phenolics are the most common matrices used for BMCs. Sometimes, for convenience of terminology, chopped prepreg, used for compression molding, is referred to as BMC. 18.3.2 Continuous-Fiber Product Forms Rovings, tows, and yarns are collections of continuous fiber. This is the basic material form...
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
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.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2011
DOI: 10.31399/asm.tb.cfw.t52860065
EISBN: 978-1-62708-338-6
... creel ( Fig. 6.5 ) is simply a shelf from which the fiber can be pulled from the center of the bundle without tension but with twist. Including twist has consequences, as shown subsequently. Fig. 6.5 Stationary creel Twist Considerations The bundle of prepreg or dry fibers called tows...
Abstract
This chapter addresses the hardware requirements for filament winding, from elementary processing equipment to more advanced systems. The chapter describes the equipment, defines how it is best used, and presents real-life examples. It describes a helical horizontal filament winding machine system and a vertical winding machine. The chapter provides information on in-plane (polar) winders and several types of creels, namely stationary and no twist, rotating, braking, and combinations thereof. Comprehensive descriptions of mandrel designs used in filament winding are presented in text and illustration. The chapter also reviews process control of filament winding parameters, including for some specialized winding processes and unique component types.
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
... can obstruct resin flow into unimpregnated areas during cure. This is sometimes found in pultruded composites but also in prepreg-based composites. Prepreg materials developed with high fiber tensions can reduce the fiber tow permeability. In this situation, the initial penetration of the resin...
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
Pressure Vessel Design, Fabrication, Analysis, and Testing
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 September 2011
DOI: 10.31399/asm.tb.cfw.t52860115
EISBN: 978-1-62708-338-6
... prepreg), or prepreg wound (preimpregnated tow respooled and delivered frozen to the customer by specialty prepreggers). The listed resins are just a small fraction of the resins used but represent the various temperature and processing classes in current production today. Typically, the higher...
Abstract
The necessity of developing the lightest-weight structures with sufficient strength was the driving factor for the development of filament-wound composite pressure vessels. This chapter presents a brief history of the development of rocket motor cases (RMCs), followed by a comparison of the advantages of composites over metals for RMCs. A discussion on a typical design, analysis, and manufacturing operation follows. The chapter introduces the basic design approach and shows some sizing techniques along with example calculations. It discusses the processes involved in the testing of the composite pressure vessel.
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
... exceeds the flatwise tensile (through-the-thickness) strength of the composite, the laminate will delaminate. Composites are susceptible to delaminations (ply separations) during fabrication, assembly, and in service. During fabrication, foreign materials, such as prepreg backing paper, can...
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
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
..., or textile techniques such as weaving or braiding can be used to form a near-net preform. To form unidirectional prepreg, tows are precoated with the interfacial protection system and filament wound on a drum, which can be prepregged with the ceramic matrix precursor material or held together with a fugitive...
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
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
...), methyl methacrylate (improved weatherability), and diallyl phtalate, which has low viscosity and is often used for prepregs. The properties of the resultant polyester are strongly dependent on the crosslinking or curing agent used. One of the main advantages of polyesters is that they can be formulated...
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
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
... in the composite interlayer and do not penetrate the fiber tows ( Ref 20 ). The most common method of interlayer toughening is through adding preformed particle-modified resin on the surface of the prepreg, which, when consolidated and cured, results in an interlayer-toughened composite. However, this same method...
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
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
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
... of Carbon Fiber-Epoxy Prepreg ASTM D 4018-99(2008) Standard Test Methods for Properties of Continuous-Filament Carbon and Graphite-Fiber Tows ASTM D 5687/D 5687M-95(2007) Standard Guide for Preparation of Flat Composite Panels with Processing Guidelines for Specimen Preparation ASTM D 5947-06...
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
Impact Response of Composites
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.tb.omfrc.t53030193
EISBN: 978-1-62708-349-2
... 5 ). The impact parameters that influence the damage mechanism are the area, velocity, and mass of the projectile that impinges on the composite part. Material characteristics that affect the damage tolerance and mechanism of failure are the type of fiber, fiber tow structure, fiber volume, weave...
Abstract
As fiber-reinforced polymeric composites continue to be used in more damage-prone environments, it is necessary to understand the response of these materials when subjected to impact from foreign objects. This chapter provides an overview of the analysis methods for impact-damaged composites. It discusses the causes and effects of various failure mechanisms in composite materials. The failure mechanisms covered are brittle-matrix composite failure, tough-matrix composite failure, thermoplastic-matrix composite failure mechanisms, untoughened thermoset-matrix composite failure mechanisms, toughened thermoset-matrix composite failure mechanisms, particle interlayer-toughened composite failure mechanisms, and dispersed-phase, rubber-toughened thermoset-matrix composite failure mechanisms.
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