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AE 537 Lecture 1 introduction

The document discusses composite materials in aerospace structures, emphasizing the importance of structural integrity and weight reduction for cost efficiency. It outlines the design process, classification of composites, and various factors affecting their performance, including fiber and matrix types. The document also highlights the advantages and drawbacks of composites, particularly in the context of aerospace applications.

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mohammad ksasbeh
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8 views

AE 537 Lecture 1 introduction

The document discusses composite materials in aerospace structures, emphasizing the importance of structural integrity and weight reduction for cost efficiency. It outlines the design process, classification of composites, and various factors affecting their performance, including fiber and matrix types. The document also highlights the advantages and drawbacks of composites, particularly in the context of aerospace applications.

Uploaded by

mohammad ksasbeh
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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COMPOSITE MATERIALS

AE 537

Introduction
AEROSPACE STRUCTURES

Aeronautics and Astronautics deal with three major categories of


structures:
1. Aircraft (atmospheric vehicles)
2. Launch vehicles
3. Space structures

Structure Design Process:


Assure “structural integrity” while minimizing cost
In aerospace structures, cost often means weight .
Why? Saving a pound of weight means more
- payload (extra passengers, more satellites)
- fuel (longer distance, longer duration)
Amount industries are willing to pay to save a pound of weight:
Satellites $10,000 - $20,000 (w/o servicing)
Transport Aircraft $100 - $200
General Aircraft $25 Automobile ∼ $0.00
Sometimes willing to pay for performance
FACTORS DETERMINING STRUCTURE COST

• Material cost
• Waste amount
• Manufacturing
• Subassembly/assembly
• Durability and maintenance
• Useful life
An engineer must consider all these. In AE 537, we will focus on
“composite structural performance and integrity” and methods to
assess such integrity.
Definition of structural integrity: “Capability of a structure to carry
out the operation for which it was designed.”
Many aspects: • Required loads
• Required deformations
• Corrosion resistance (e.g., no breach of pressure vessels)
Many aspects to “failure” (we will discuss later)
COMPOSITE MATERIALS

Hybrid materials combine the properties of two (or more)


monolithic materials, or of one material and space.
MIMICKING NATURE TO MAKE
COMPOSITE MATERIALS AND STRUCTURES
BIO-INSPIRED STRUCTURES MIMICKING
NATURE
COMPOSITE MEMBRANE STRUCTURE OF A
LIFE CELL

• Thickness 7.5 nm

• 2 parallel lines:
- Intracellular:
inner Leaflet
- Extracellular,
outer leaflet

• Bi-lipid layer and


protein in between

• By weight (Half
protein and half lipid
COMPOSITE STRUCTURE ANALYSIS AND
OPTIMIZATION
CHALLENGES FOR AEROSPACE MATERIALS
AND STRUCTURES

Create material systems with optimized MULTI-functionality by design.

Integration of diverse features/requirements into useful


materials and design tools
ENGINEERING SCOPE

- Optimizing function in a multifunctional material


- Capturing features (compositional, spatial, morphological)
that control the function of a particular material system
- Feature population/distribution
- Couple dependence of properties on material feature
- Evolution of defected structure
- Mathematical framework to enable multifunctional design
- Reduce complexity
- Incorporate variability in design
- Processing techniques available to synthesis multifunctional
structures.
DESIGN ARCHITECTURE MATERIALS

The modulus–density space, with the contours of the specific modulus E/𝜌 .
Part of the space is occupied by material, while part is empty (the “holes”).
CLASSIFICATION OF COMPOSITES
3. STRUCTURAL SANDWICH PANEL
1. PARTICULATE COMPOSITES: (A)
DISPERSION STRENGTHENING

- Tungsten carbide-cobalt (WC-Co)


1. PARTICULATE COMPOSITES: (B)
PARTICULATE STRENGTHENING

Usually, particulate composite materials have isotropic properties or sometimes called quasi-isotropic
2. FIBERS REINFORCED COMPOSITES

❖Continuous
➢ Unidirectional
➢ Cross ply of fabric
➢ Multidirectional

❖ Discontinuous
➢ Unidirectional
➢ Randomly oriented
2. FIBER REINFORCED COMPOSITE ANALYSIS

1. Fiber/matrix interaction
- Types and classes
- Interface characteristics
(roughness, chemical/physical bond)

2. Lamina anisotropic elastic properties

3. Laminate characteristics

4. Structure level analysis


FIBER PARAMETERS
FIBER PARAMETERS

Think of two more parameters?


➢ Length
• Long fibers
• Short fibers
➢ Material
• Mechanical properties
• Electrical properties
• Thermal properties
• Magnetic properties
• Repair easiness
FIBER PARAMETERS-EFFECT EXAMPLES

Concentration:
➢ Increases the carrying capacity in general
➢ Increase cost and weight

Distribution:
➢ Affects the directional carrying capacity
FIBER PARAMETERS-EFFECT EXAMPLES

Length: ( Affects carrying capacity in general)


❖ Long Fibers
➢ Easy to orient
➢ Easy to process
➢ Higher impact resistance
➢ Dimensional stability
❖ Short Fibers
➢ Low Cost
➢ Fast cycle time fabrication procedure
➢ Easy to work with
➢ Short fibers have fewer flaws and therefore have higher
strength
FIBER PARAMETERS-EFFECT EXAMPLES

Orientation :
❖ One direction orientation
➢ High stiffness and strength in that direction
➢ Low stiffness and strength in other directions

❖ Multi-direction orientation
➢ More direction independent
FIBER PARAMETERS-EFFECT EXAMPLES

Shape :
❖Circular
➢ Most common shape ( easy to manufacture and handle)
❖Hexagon and square shapes:
➢ Give high packing factors and higher strength

Hexagon and square shapes advantages do not


outweigh the difficulty in handling and processing.

(True/ False )?
FIBER PARAMETERS-EFFECT EXAMPLES

Materials :
➢ Graphite and aramids have high strength and stiffness
➢ Glass has low stiffness but cost less

In some designs the requested properties have a higher


priority than the cost, especially in aerospace structures .
MATRIX FACTORS

What are the matrix factors which contribute to


the mechanical performance of composites?
Usually, matrix is made of homogenous material and the
only factor is the material of the matrix.

Matrix Functions:
➢ Binds fibers together
➢ Protects fibers from environment
➢ Shielding from damage due to handling
➢ Distributing the load to fibers.
FACTORS OTHER THAN
FIBER AND MATRIX

Fiber-matrix interface
➢ Chemical bonding.
➢ Mechanical bonding.
FIBER TYPES

➢Glass Fiber (first synthetic fiber)


➢Boron (first advanced fiber)
(limited use after using carbon)
➢Carbon
➢Silicon Carbide
TYPES OF MATRICES

➢Polymers
➢Metals
➢Ceramics
POLYMER MATRIX

❖Thermosets
➢polyester
➢epoxy
➢polymide
❖Thermoplastics
➢polypropylene
➢polyvinyl chloride
➢Nylon
METAL MATRIX

❖Aluminum
❖Titanium
❖Copper
CERAMIC MATRIX

❖Carbon
❖Silicon Carbide
❖Calcium Alumino-Silicate
❖Lithium Alumino-Silicate
WHY DO FIBERS HAVE THIN DIAMETER?

❖Less flaws
❖More toughness and ductility
❖Higher flexibility
Thin Fiber

Thick Fiber
LESS FLAWS

As the fibers become smaller in


diameter, the chances of an
inherent flaw in the material are
reduced. A steel plate may have
strength of 100 ksi (689 MPa),
while a wire made from this steel
plate can have strength of 600 ksi
(4100 MPa).

Strength of a carbon fiber increases with the decrease in its


diameter
MORE TOUGHNESS AND DUCTILITY

❖Fiber-matrix interface area is inversely


proportional to the diameter of the fibers

❖Higher surface area of fiber-matrix interface


results in higher ductility and toughness, and
better transfer of loads.
MORE FLEXIBILITY

❖Flexibility is proportional to inverse of


➢Young’s modulus
➢Fourth power of diameter
❖Thinner fibers hence have a higher flexibility
and are easy to handle in manufacturing.
ADVANTAGES OF COMPOSITES

❖Specific Strength and Stiffness

❖Fatigue Life

❖Dimensional Stability (low geometric change under


environmental conditions such as change in temperature)

❖Corrosion Resistance
DRAWBACKS OF COMPOSITES

❖High cost of fabrication of composites


❖Complex mechanical characterization
❖Complicated repair of composite structures
❖High combination of all required properties may
not be available

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