MEG 495/695 Special Topics: Entertainment Engineering

Introduction to Composite Materials

Brendan J. OToole, Ph.D. Department of Mechanical Engineering Howard R. Hughes College of Engineering University of Nevada Las Vegas Office: TBE B-122 Phone: (702) 895 - 3885, Fax: (702) 895 - 3936 e-mail: [email protected] These notes are available at: http://www.egr.unlv.edu/~bj
1
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Materials In Entertainment Engineering

Designer: Cindy Chinn Artist: Cindy Chinn Date: 1987

University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Materials Used in Entertainment Engineering

Depends on how you define entertainment engineering:
Props for shows Ornamental structures Architectural simulations/re-creations Hobby activities: model aircraft, race cars, model rockets ???

For today, I will focus on:

Sculpture materials for re-creations or original designs Mold making materials Polymers and composites for structural applications
3
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Clay Sculptures for Slot Machine Handles

4
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Foam Sculpting
Designer: Rhino Cast Sculptor: Cindy Chinn Date: 2002 This is a sample we did to demonstrate the process of foam sculpting. Many statues you see in Las Vegas are done using this process.

The original model was scanned in 3D, then enlarged and cut by CNC computer milling. From there we completed the detail as shown in the top section. Then a thin layer of drywall mud was applied to add firmness to the surface. A hard coating of polymer is applied to protect the statue from the elements. Finally, the statue is painted to match the desired look - in this case, weathered stone. The entire process took 2 days to complete.
5
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Processing of ReCrete Foam At UNLV

Ice Bath Mixing for 3.5 Min.

Water Bath

Ambient

Foam Rises and Stays in Molds for 30 Min.

Post Cure at 66OC for 4 Hours

Fabricated Foam

Foam Classifications
Many materials can be foamed (polymers and metals) The most common types of foam used for molding:
Expanded Polystyrene
Usually white Pilly (Styrofoam coffee cups, cheap ice chests, etc.) Can be cut with a hot wire

Extruded Polystyrene
Usually blue, panels used for home insulation Can be cut with a hot wire

Rigid Polyurethane
Stronger and stiffer than polystyrene Cannot be cut with a hot wire (toxic fumes) Can be sanded easily to get a fine surface
7
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Foam Cutting

8
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Architectural Foam Structures

Realm of Design, Henderson NV

9
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Products Made Possible With Composite Materials

10
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Composites
Composites are made from two or more distinct materials that when combined are better (stronger, tougher, and/or more durable) than each would be separately.

The word usually refers to the fiber-reinforced metal, polymer, and ceramic materials that were originally developed for aerospace use in the 1950s.
Although composites are a "high-technology" development, to some extent they mimic the features of living organisms such as the microstructures of wood and bioceramics like mollusk shells. The fibers and matrix of advanced composites may be combined using a variety of fabrication processes, with the choice depending on the desired alignment of fibers, the number of parts to be produced, the size and complexity of the parts, and so on. Perhaps best known for their use in aerospace applications, advanced composites are also used by the automotive, biomedical, and sporting goods markets. In addition, these strong, stiff, lightweight materials are seeing increased use in the rehabilitation, repair, and retrofit of civil infrastructure--including, for example, as replacement bridge decks and wrapping for concrete columns.

An Example of a Natural Composite

Composites do occur in nature--e.g., in tree trunks, spider webs, and mollusk shells. A tree is a good example of a natural composite, consisting of cellulose (the fibrous material) and lignin (a natural polymer) forming the woody cell walls and the cementing (reinforcing) material between them.

Complements of: http://www.ccm.udel.edu/

11
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Manufacturing Fiberglass Composites

12
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Some Characteristics of Composites

Advantages
High Mechanical Properties Flexibility of Design Options Ease of Fabrication Light Weight Corrosion Resistant Impact Resistant Excellent Fatigue Strength

Disadvantages
Brittle Failure Mechanisms High Material Costs High Manufacturing Costs Temperature Limitations Actual Mechanical Properties not Always as Good as Expected Mechanical Properties Very Process Dependent

13
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Major Classifications of Composites

Polymer Matrix
Material Systems
Thermoset & Thermoplastic Resin Systems Glass, Carbon, Aramid Reinforcing Fibers

Product Classifications
Engineering Composites (lower cost, injection molded parts, fiberglass tooling and components) Advanced Composites (high performance and higher cost materials)

Carbon Carbon Composites Metal Matrix Ceramic Matrix Reinforced Concrete

14
MEG 495/695 Entertainment Engineering BJO 2005

University of Nevada Las Vegas

9 8 7 6 5 4 3 2 1 0
SAE 1010 Steel AISI 4340 Steel

Specific Gravity For Several Materials

University of Nevada Las Vegas

17-7 PH Stainless

AL 6061-T6

AL 7178-T6

Ti-6A1-4V High Strength Carbon FiberEpoxy (unidirectional) High Modulus Carbon FiberEpoxy (unidirectional) E-glass Fiber-Epoxy Kevlar 49 Fiber-Epoxy (unidirectional)

Specific Gravity For Several Materials

MEG 495/695 Entertainment Engineering BJO 2005

Specific Gravity is the density of the material compared to the density of water.

Carbon Fiber-Epoxy (quasiisotropic)

15

Specific Strength & Specific Modulus

16
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Materials Found in Composites

Reinforcing Fibers (or particles) Matrix (holds fibers together) Others may include
Coatings
Improve bonding and load transfer at the fibermatrix interface

Fillers
Added to polymers to reduce cost and improve dimensional stability

17
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Basic Building Blocks of Fiber-Reinforced Composites

Unidirectional Continuous

Bi-directional Continuous (e.g. woven fabrics)

Unidirectional Discontinuous

Random Discontinuous

Materials are formed into layers called lamina (ply, layer). Lamina can be 0.004 - 0.04 inches thick.

Lamina with different fiber orientations (or different materials) are stacked to make laminates.
18

University of Nevada Las Vegas

MEG 495/695 Entertainment Engineering

BJO 2005

Fiber Reinforcements
Fibers occupy the most volume in a high performance composite and carry most of the applied load. Fiber type, quantity and orientation have a major influence on the following properties of the composite:
Specific Gravity Tensile Strength & Modulus Compressive Strength & Modulus Fatigue Strength Electrical & Thermal Conductivity's Cost
19
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Fiber Properties Better Than Bulk Material Properties

Mechanical properties of fibers can be orders of magnitude greater than the same properties for the bulk material used to form the fibers. The bulk material may have flaws and defects which reduce stiffness and more noticeably, the strength. Process used to manufacture the fibers eliminates or reduces flaws resulting in better mechanical properties.
20
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Fiberglass Reinforcement

21
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Glass Fibers
Raw Materials:
silica sand, limestone, boric acid, etc.

Four major types used for composites:

E-glass: good strength & electrical resistivity S-glass: 40% higher strength, better retention of properties at elevated temperatures C-glass: corrosion resistant Quartz: low dielectric properties, good for antennae and radomes
22
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Fiberglass Forms for Composites

Rovings: used directly for some manufacturing processes (pultrusion, winding). Fabrics: made by weaving continuous rovings just like textiles
fabrics are usually compared by weight. Most glass fabrics weigh between 12 and 40 oz./sq. yd. The thickness varies from 0.02 to 0.04 inches.

Fiberglass Mats
Chopped Strand Mat: randomly oriented 1-2 inch fibers Continuous Strand Mat: unchopped spiraled fiber Surface Veil: decorative fine weave which minimizes telegraphing of primary structure
23
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Carbon Fiber Reinforcement

24
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Carbon Fibers (Graphite)

High Strength, High Modulus Fibers First Developed in the 1950s. Typical carbon fiber diameters are in the range from 5-10 m. Continuous carbon fibers are grouped together in bundles called TOWS. There can be between 400 and 320,000 filaments per tow. Most tow sizes used in composites are in the 3k to 12k range. Carbon fiber tows can be processed in to composites directly or woven into fabrics
25
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Comparison of 3K & 6K Carbon Fiber Fabrics

100% CARBON FABRIC - 3K x 3K - PART # 3570-30AQ 100% CARBON FABRIC - 6K x 6K - PART# 61052-50TQ

PART #: 3570-30AQ
Weight: 195g/5.7oz Width: 76cm/30" Weave Type: Plain Warp Count: 12 ends/" (492/m) Fill Count: 13 pics/" (492/m) Warp Fiber: 3k Amoco T300 Fill Fiber: 3k Amoco T300

PART #: 61052-50TQ
Weight: 362g/10.5oz Width: 127cm/50" Weave Type: 2x2-Twill Warp Count: 11 ends/" (433/m) Fill Count: 11 pics/" (433/m) Warp Fiber: 6k TORAY T400 Fill Fiber: 6k TORAY T400

Thickness: 0.009/0.0076 (dry/laminate)

Thickness: 0.024/0.017 (dry/laminate)

PART #

Price Format $Lin/yd

List $US 20.58

1+ Roll 13.27

2+ Roll 12.25

5+ Roll 11.22

10 + Roll 10.19

25 + Roll 9.16

PART #

Price Format $Lin/yd

List $US 43.00

1+ Roll 28.68

2+ Roll 26.53

5+ Roll 24.38

10 + Roll 22.23

25 + Roll 20.08

3570-30AQ

61052-50TQ

$m2

29.54

19.05

17.57

16.10

14.62

13.14

$m2

37.03

24.70

22.85

20.99

19.14

17.29

FABRIC Carbon: 195g/5.7oz @ 76cm/30", Plain, 12.5x12.5pic, 3k x 3k, Amoco T300

FABRIC Carbon: 362g/10.5oz @ 127cm/50", 2x2-Twill, 11x11pic, 6k x 6k, TORAY T400

http://www.carb.com/carbon.html
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

26

Organic Fiber Reinforcement (Kevlar, Spectra, )

27
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Organic Fibers
Aramid (Kevlar, Twaron)
First introduced commercially in 1971 Its first commercial applications were in tires, industrial belts, bullet proof vest, high strength cloths, and composite structures Several Types of Kevlar
Kevlar 29: high toughness Kevlar 49: high modulus Kevlar 149: ultra high modulus

In general Kevlar has high tensile strength and good damage tolerance but poor compressive strength. Kevlar can have problems bonding to other resins
28
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Carbon/Kevlar Hybrid Fabrics

29
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Standard Fabric Weave Patterns

PLAIN WEAVE: The most simple and common of the weave patterns with warp and fill fibers crossing alternately. The most stable weave pattern. TWILL: A basic weave which enables a greater number of yarns per unit area than a plain weave, as each end floats over at least two or more consecutive picks. It looks different on each side and is characterized by a diagonal "twill" line.

SATIN WEAVE: The face of the fabric consists almost entirely of warp or fill "floats" produced when, for example, one fill fiber "floats" over three or more warp fibers and then drops under one. The two sides each have a different appearance. Typically used in the composites industry, it produces a drapable fabric which conforms easily to contoured surfaces. BASKET WEAVE: A variation of the plain weave typically used in composites, in which two or more warp fibers cross two or more fill fibers; more pliable and stronger than a plain weave, but less stable because it is looser.

LENO: A locking type of weave. Two or more warp fibers cross over each other and interlace with fill fibers, which prevents shifting of fibers in "open weave" fabrics.

30
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Matrix Materials for Composites

Have two major roles:
Transfer load to the reinforcement Protect reinforcement from adverse conditions

Three major classes of matrix materials

Polymers
Thermosets Thermoplastics

Metals Ceramics
31
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Thermoset Polymers
In general, they are liquid resins at room temperature They undergo a curing process which crosslinks their molecular structure Cannot be remelted or reprocessed More rigid than thermoplastics Can have long or short processing times Examples: epoxy, polyester, polyimides, phenolics
32
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Polyester Resins
Have dominated the market for commercial fiberglass reinforced composites. Major applications include:
boat hulls, pools, tubs, ducting, car body panels, building panels, molded furniture, tubing, etc.

Advantages: Low cost, low viscosity, fast cure time Disadvantages: Low temperature capability, poor weathering performance First patented in 1936, became widely used within 10 years
33
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Polyester Resins
Polyesters can contain substantial amounts of several ingredients:
Resin, catalyst, filler, accelerator

A variety of polyesters exist for different applications depending on the desired properties:
flexibility, toughness (bowling balls, helmets), low shrinkage, weather resistance, chemical resistance, fire resistance
34
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Epoxy Resins
Most common choice for advanced composite materials Advantages:
Better adhesion to fillers, fibers, and other substrates Corrosion protection Higher strength, Lower shrinkage Good electrical an fatigue properties

Disadvantages
Higher cost, long curing time Poor appearance (yellowish)

Applications
Potting & encapsulating for environmental protection, tooling, adhesive bonding, laminated & filament wound composites
35
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Curing of Epoxies
Epoxies start with an epoxy group Hardeners are added which react with the epoxy groups to form the cross linked polymer Curing time and temperature depend on the type and amount of hardener. Some epoxies react and cure at room temperature, others require heating to complete the reaction Cooling can slow down the reaction.
36
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Manufacturing Methods for Composite Materials

Manual Lay-up or Spray-up Vacuum Bagging Autoclave Processing Filament Winding Pultrusion Matched Die Molding (SMC) Resin Transfer Molding All of these methods are tailored for the specific materials that are being processed. Polymer chemistry plays an important role in selecting the appropriate resin for a given fabrication method.
37
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Composites Processing Summary

The processing usually involves a cycle (or multiple cycles) of applied temperature, pressure, and vacuum. Elevated temperature is used to:
Initiate and sustain chemical reaction in thermoset resins Melt thermoplastics Reduce viscosity

Pressure is used to:

Force the viscous resin-fiber material into a mold. Compact a laminate Squeeze out voids

Vacuum is used to help pull out trapped air or other gasses that may be produced during the chemical reaction.
38
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Manual Lay-up Methods for Composites

Begin with a mold
Apply mold release agent

Apply a thin layer of catalyzed resin to form a gel coat

Protects from blistering, stains, weather, etc.

Apply layer of fabric or mat reinforcing Pour, brush, or spray resin onto fiber reinforcement Use rollers to spread resin, flatten fibers, squeeze out trapped air Repeat for additional reinforcement layers Let cure.

39
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Vacuum Bag Molding Process

40
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Manual Lay-up of UNLV Human Powered Vehicle Fairing

41
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Vacuum Bagging of UNLV Human Powered Vehicle Fairing

42
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Finished Fairing

43
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

62 MPH !

44
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

2005 Tandem HPV Fabrication

45
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

2005 Tandem HPV Competition

46
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Autoclave Curing of Composites

A prepreg composite part is generally prepared in the same manner as described for vacuum bagging. The entire assembly is then placed in an autoclave that is capable of applying both heat and pressure.

47
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Pultrusion

48
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Filament Winding

49
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

Composites References
(Trade Magazines & Websites)
Trade Magazines (Offer free subscriptions) Composites Design & Application (CDA), Published by the Composites Institute of the Society of the Plastics Industry CI/SPI. Composites Technology, Ray Publishing. High Performance Composites, Ray Publishing.

Related Websites: 1. http://www.ccm.udel.edu/ 2. http://www.wwcomposites.com/ 3. http://mil-17.udel.edu/ 4. http://plastics.about.com/ 5. http://callisto.my.mtu.edu/MY472/ 6. http://www.netcomposites.com/ 7. http://www.advmat.com/ 8. http://www.sampe.org/ 9. http://www.a-c-m.com/ 10. http://www.egr.msu.edu/cmsc/ 11. http://www.compositesone.com/ 12. http://www.wicksaircraft.com/
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005

50

The End

51
University of Nevada Las Vegas MEG 495/695 Entertainment Engineering BJO 2005