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Composites
Materials (AERO95005) – Topic 11 (2019/20) 2
A B
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Examples
(Concrete) (Plastic boat hulls) (Reinforced concrete) (Plywood)
Revision – Composites
• Composite industry - grown rapidly in past 30 years
Glass-fibre reinforced polymers (GFRP or fibreglass)
Carbon-fibre reinforced polymers (CFRP).
• Composites challenge conventional materials in many applications.
• Problem;
Originally touted as the universal panacea for structural applications
Led to inappropriate use of the material and poor design
Well publicised disasters (such as RB211)
Materials (AERO95005) – Topic 11 (2019/20) 5
Revision – Composites
ADVANTAGES
High stiffness & strength at low
weight
Properties can be tailored by choice
of matrix & reinforcement
Good corrosion resistance & fatigue
properties
Toughness through multiple crack
paths
DISADVANTAGES
Higher cost than most conventional
materials
Low strength & toughness in certain
directions
Most light (polymer) composites
unsuitable for high temperatures
Materials (AERO95005) – Topic 11 (2019/20) 7
Composites –
Constituents
Materials (AERO95005) – Topic 11 (2019/20) 8
Fibres
Materials (AERO95005) – Topic 11 (2019/20) 9
Matrices
Materials (AERO95005) – Topic 11 (2019/20) 10
Vinylester Very high chemical/environmental resistance Post-cure required for good properties
Higher mechanical properties than polyesters High styrene content
Higher cost than polyesters (£2-4/kg)
High cure shrinkage
Epoxies High mechanical and thermal properties More expensive than vinlyesters (£3-
High water resistance 15/kg)
Long working times available Critical mixing
Resistance upto 140°C wet/220°C dry Corrosive handling
Low cure shrinkage
Materials (AERO95005) – Topic 11 (2019/20) 12
Thermoplastic Matrices
Materials (AERO95005) – Topic 11 (2019/20) 13
Other Matrices
Phenolics
• Good fire-resistance, but brittle
• Typical cost: £2-4/kg
Cyanate Esters
• Dielectric properties & upto 200°C (wet).
• Typical cost: £40/kg.
Polyurethanes
• High toughness
• Typical cost: £2-8/kg
Bismaleimides (BMI)
• Perform upto 230°Cwet/250°C dry
• Aircraft engine inlets
• Typical cost: >£50/kg.
Polyimides
• Up to 250°C wet/300°C dry).
• Missile & aero-engine components.
• Extremely expensive (>£80/kg)
Materials (AERO95005) – Topic 11 (2019/20) 14
Composites
Materials (AERO95005) – Topic 11 (2019/20) 16
Composite Architecture
Materials (AERO95005) – Topic 11 (2019/20) 17
Composite laminates
from unidirectional plies
2D weaves
(lower in-plane stiffness & strength)
3D weaves
(lower in-plane stiffness & strength)
Materials (AERO95005) – Topic 11 (2019/20) 18
1K Tows 3K Tows
Materials (AERO95005) – Topic 11 (2019/20) 19
https://www.youtube.com/watch?v=CLjTixmFUkM
Materials (AERO95005) – Topic 11 (2019/20) 20
Architectures – Woven
Materials (AERO95005) – Topic 11 (2019/20) 22
Plain Twill
Through-thickness Reinforcement
– Stitching, Tufting & Z-pinning
Materials (AERO95005) – Topic 11 (2019/20) 26
https://www.youtube.com/watch?v=IeST0vfDuhw
Materials (AERO95005) – Topic 11 (2019/20) 27
Mechanical Properties
Materials (AERO95005) – Topic 11 (2019/20) 28
Ecomposite E f V f Em (1 V f )
V f (1 V f )
Ecomposite 1
E Em
f
Ply splitting
Microbuckling
Delamination
Materials (AERO95005) – Topic 11 (2019/20) 32
Tensile Failure
Materials (AERO95005) – Topic 11 (2019/20) 34
Compressive Failure
Materials (AERO95005) – Topic 11 (2019/20) 36
Composites - Compression
Materials (AERO95005) – Topic 11 (2019/20) 37
sy
Tension in y
Failure envelope
sx
Compression in x Tension in x
s x, s y
Compression in y
Materials (AERO95005) – Topic 11 (2019/20) 38
sy
Tension in y
sx
Compression in x Tension in x
s x, s y
Within envelope
– no failure
Compression in y
Materials (AERO95005) – Topic 11 (2019/20) 39
sy
Tension in y
sx
Compression in x Tension in x
s x, s y
Outside envelope
– failure!!!
Compression in y
Materials (AERO95005) – Topic 11 (2019/20) 40
sy
Tension in y
f(sx,sy)?
sx
Compression in x Tension in x
Compression in y
Materials (AERO95005) – Topic 11 (2019/20) 41
Compression
Tension
Objectives:
• Comparison and evaluation of failure criteria
• Which ones work the best ? (if at all)
• Representatives for all the most ”important” failure criteria were invited to
participate
• Laminate configurations, load cases and input data (measured stiffnesses,
strengths, …) defined by QinetiQ
Materials (AERO95005) – Topic 11 (2019/20) 47
• Maximum stress and strain criteria - do not take interactions into account;
a particular problem when s2 and t12 dominate.
• Interactive criteria do not take into account the failure mode – only give a
failure index.
• To represent underlying physics; at least one equation for each failure mode
Prof Pinho has won the World Wide Failure Exercise (WWF)
Materials (AERO95005) – Topic 11 (2019/20) 51
Toughness of Composites
Toughness of Composites
Toughness of Composites
• A crucial issue is bonding of the
reinforcement to the matrix;
Too weak - the composite will
have insufficient strength &
stiffness.
Too strong - composite may be
unacceptably brittle.
Materials (AERO95005) – Topic 11 (2019/20) 55
Delamination
Materials (AERO95005) – Topic 11 (2019/20) 56
https://www.youtube.com/watch?v=ob-3Coej8rs
Materials (AERO95005) – Topic 11 (2019/20) 59
G from
finite element model
Materials (AERO95005) – Topic 11 (2019/20) 61
G <GIC
NO GROWTH
Materials (AERO95005) – Topic 11 (2019/20) 62
G >GIC
DAMAGE
GROWTH!!!!
Materials (AERO95005) – Topic 11 (2019/20) 63
Applications
Materials (AERO95005) – Topic 11 (2019/20) 64
Boeing 787
Materials (AERO95005) – Topic 11 (2019/20) 69
A350
Materials (AERO95005) – Topic 11 (2019/20) 70
Composite Fuselage?
What are the issues?
• Environmental Threats?
Runway debris (lower fuselage)
• Environmental Threats?
Hail (upper fuselage on ground)
• Loading conditions?
Impact (ground vehicles)
• Manufacturing Issues?
Lightning strike (once per year)
• Ownership Issues?
• Loading conditions?
Mainly tensile (pressurisation), cyclic
Lower fuselage (compression)
Bending/Torsion
• Manufacturing Issues?
Joints/curved structures
‘Springback’
• Ownership Issues?
Inspection/repair of curved structure
Acoustic issues
Materials (AERO95005) – Topic 11 (2019/20) 71
Structural Wt 5,647 lb
(Including Gun
Paks and Strakes)
Metallics 4,137 lb
Aluminum Carbon/BMI
Steel and Nickel Fiberglass/BMI
Titanium Acrylic
Carbon/Epoxy Other
Fiberglass/Epoxy
CC22643041.ppt
Materials (AERO95005) – Topic 11 (2019/20) 72
V22 Osprey
A400M
Materials (AERO95005) – Topic 11 (2019/20) 75
Tiger EH101
Materials (AERO95005) – Topic 11 (2019/20) 76
http://www.youtube.com/watch?v=tZhH2B-EI1I&feature=related
03:00 – 09:00
Materials (AERO95005) – Topic 11 (2019/20) 80
Infrastructure
Materials (AERO95005) – Topic 11 (2019/20) 83
Wind Turbines
Materials (AERO95005) – Topic 11 (2019/20) 84
Automotive Applications
Materials (AERO95005) – Topic 11 (2019/20) 85