A Comprehensive Guide to Composites: Processes & Procedures from the Professionals

A Comprehensive Guide to Composites

Processes and Procedures from the Professionals

by Kevin Fochtman

Second Edition

Aviation Supplies & Academics, Inc.

7005 132nd Place SE

Newcastle, Washington 98059-3153

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©2012 Advanced Composite Education Services

All Rights Reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopy, recording, or otherwise, without the prior written permission of the copyright holder. While every precaution has been taken in the preparation of this book, the publisher and Kevin Fochtman assume no responsibility for damages resulting from the use of the information contained herein.

Published 2014 by Aviation Supplies & Academics, Inc.

ASA-COMP-101-EB

ISBN 978-1-61954-205-1

Direct inquiries to:

Advanced Composite Education Services

11302 Steele St. Ste. A

Lakewood, WA 98499

253-537-0966

www.learncomposites.org

Preface

Welcome to A Comprehensive Guide to Composites. It has long been my dream to provide educators, students, hobbyists and anyone with an interest and a passion for composites, with a how-to guide from the trenches. There are many fine books on composites, no doubt from folks as passionate as myself. But my goal was to download thirty years of inside knowledge and help folks understand the real nitty-gritty of composite production.

Of course I was not alone in getting this on paper. First a big thank you to Tactical Marketing Group comprised of Kevin Hayes, and Doug Hudak. These two professionals were not only instrumental in completing this book project, but have delivered marketing support and collateral materials for our national roll-out. Plus, they are two of the funniest guys I’ve ever met.

Also, a big thank you to Chris Herrero who worked tirelessly taking photographs, building projects and being the all-around go-to guy. Chris, you delivered when we needed you most.

There are numerous industry pros and educators to acknowledge, but that would fill several pages. You folks know who you are and you know where my gratitude lies. Thank you so much.

Last, but not least, I would like to thank my family for all their advice, wisdom and critiques: Kevin Jr. and Kellie, you guys are my inspiration to keep driving for the goal line. Cassandra, my beautiful wife and partner in all my endeavors, thank you for your love, faith and continued support.

May this book inspire the composite creativity in all who read it.

Kevin Fochtman

Introduction

Objectives

A. Defining composites

B. Typical applications

C. Deciding on a program level

According to the Advanced Composite Materials Association (ACMA), the U.S. dominates the advanced composites industry in manufacturing, product research and distribution. There are more than 500,000 people employed in upwards of 7,000 advanced composite companies, producing everything from airplane bodies to sports equipment and automobile parts. The $70-billion-dollar industry’s projected ten-year growth rate is nearly 8%, which presents an array of opportunities for a highly skilled worker.

What Are Advanced Composites?

Composites are also known by the industry term fiber-reinforced polymer or FRP. Advanced composites are characterized by the use of expensive, high-performance resin systems and high-strength, high-stiffness fiber reinforcement.

A polymer matrix resin, sometimes referred to as plastic, is either thermoplastic or thermoset resin. A thermoplastic is a polymer that becomes pliable or moldable above a specific temperature, and returns to a solid state upon cooling. A thermoset is polymer material that irreversibly cures. The cure may be done through heat (generally above 350°F), through a chemical reaction (two-part epoxy, for example), or irradiation such as electron beam processing. Common thermoset resins include polyester, isopolyester, vinyl ester, epoxy, and phenolic. To reinforce the resins we use fibers such as glass, carbon, aramid, graphite or other reinforcing material.

The combination of these materials results in a discernible reinforcing function in one or more directions along the aspect ratio (length to thickness). FRP composite may also contain fillers, additives, and core materials.

There are a number of exotic resins and fibers used in advanced composites, however, epoxy resin and reinforcement fiber of aramid, carbon, or graphite dominates this segment of the market. These materials have been adopted by an enormous range of industries touching our everyday lives. Advanced composites provide high strength-to-weight ratios which enables engineers to design high performance parts. ACMA estimates that more than 50,000 new products could utilize advanced composite materials.

Composite Applications

Aerospace

Composites used in commercial airliners have made tremendous strides over the past 40 years. The first 747 that rolled out of Boeing’s Everett, Washington production facility contained just 1% composite materials. Today more than 50% of the 787 Dreamliner is built with composites, including the world’s first all-composite fuselage. The Airbus A350 XWB is more than 50% composites, as it prepares to enter service in 2014. Typical composite uses include: air frames, wing spars, tail-fins, spoilers, fuel tanks, bulkheads, flooring, helicopter rotor blades, propellers, pressurized gas containers, radomes, engine nacelles, air distribution ducts, seat components, access panels, and more. Carbon fiber composites are used in elevated temperature applications such as disc brakes and static components in jet engines. Rocket motor casings and rocket launchers are also frequently made of reinforced plastics.

Automotive Engineering

Mandates to increase fuel economy over the next twenty years are driving weight reduction throughout the assembly. Advanced composites (carbon, aramid, graphite) are not as frequently used as glass-reinforced plastics (GRP) because of the costs. Typical uses include: car and truck body moldings, panels and doors, fascias, bumper moldings, and trim packages. Based on the high energy-absorbing capacity of composites, many manufacturers use them in controlled crush components.

Bioengineering

Composites are widely used as prostheses for amputees. In running, carbon fiber prosthetics ‘flex’ which provides for kinetic energy storage, thus greatly increasing a runner’s performance level. As arms and hands, composites are light, strong and malleable. The bebionic3, features microprocessor controlled motors in each finger. This allows for a multitude of grips and hand positions previously out of reach with wood and rubber models.

Chemical Engineering

Typical uses in this sector include: pressure vessels, containers, valves and pipe-work.

Construction/Civil Engineering

Typical uses include folded-plate structures, cladding panels, decorative architectural panels, ducting, racking, pipe work, gutters, water tanks, form work for concrete, and light-duty structures such as pedestrian bridges. Composites are also used to retrofit and upgrade existing bridges through externally applied impact-containment supports and patches over concrete.

Electrical Engineering

Typical applications include radomes, insulators, printed circuit boards, and casings for electronic equipment. Wind-blades in generator designs are now almost all made of composites because of their strength and durability.

Marine Engineering

Fiberglass hulls have been around for generations, but advanced composites are making serious inroads. The world’s most expensive composite yacht was recently completed in China. The superstructure is carbon fiber with Nomex honeycomb core, the hull is glass/Kevlar foam sandwich, and the interior is light-weight oak cabinetry using honeycomb panels. To help reduce weight, virtually every aspect of the boat was custom built, including carbon fiber hatches, port lights, ladders, and even hinges, all built specifically for the vessel. High specific compression properties also make composite materials attractive for submersibles and submarine structures.

Sport

In no other sector has the use of composites become more visible than sporting goods. Manufacturers quickly adopted new materials like carbon and boron fiber composites to replace wood, aluminum, and steel in nearly every category imaginable. The rush to composites began with vaulting poles and now encompasses tennis rackets, baseball bats, golf clubs, fishing rods, boats, oars, archery equipment, canoes, kayaks, surf boards, wind-surfers, skateboards, skis and ski-poles, bicycles (and wheel-sets), helmets, body armor, and much more.

So You are Ready to Start a Shop?

For simplicity’s sake, we have divided composites training programs into three levels—entry, intermediate and advanced. In a nutshell, the program differences involve increasingly more advanced equipment and complex production outcomes. Before laying out any training program, let’s consider some factors that may help you determine a course.

There are three basic outcomes for students who undertake composites training:

1. Some students will advance into vocational technical training, enabling them to work in a wide range of industries as repair/fabrication technicians.

2. Some students will follow the university engineering and design path, enabling them to develop new structures and products using advanced composites. Again, the range of jobs and industries is wide open.

3. Also on the university path, there are students who find the materials fascinating to work with and will go on to promising material science careers.

An important consideration then, is to consider your student’s next steps. Whether providing a short module on composites or preparing tomorrow’s aerospace engineer, there are several questions to ask of your district, employers and students as you address those next steps.

Your Regional Landscape

How many automotive, aerospace or consumer goods manufacturers operate within your region? Do you have any colleges offering composites science and/or engineering? How about trade schools? Do you have any chemical plants within your footprint? With 7,000 U.S.-based companies involved in the composites industry, there is a strong likelihood that advanced composites companies are operating in your own backyard. Workforce demands should factor in your decision on whether your shop is entry, intermediate, or advanced.

The Pacific Northwest has two high schools within 10 miles of each other that both have advanced programs. One spent roughly $30,000 and the other has budgeted approximately $100,000. Their students will come away with prerequisite skills to enter technical training courses at the next level, and proceed directly to on-the-job training with manufacturers, or step into four-year college engineering or science curricula based around composites. And don’t discount the entrepreneurial spirit that still exists in all parts of the country. When an intrepid inventor learned that the local high school was offering composites fabrication, he approached the class for help with his newfangled idea for a camcorder mount. At last word, he was very happy with his prototypes and was busy raising seed capital.

The Takeaway Skills

Test Your Knowledge: Chapter 1

1. Composites are also known by the industry term FRP,