Composites 201
John P. Busel, F.ACI, HoF.ACMA
VP, Composites Growth Initiative
American Composites Manufacturers Association
2
September 21-24, 2020 / www.theCAMX.org
• To build on the information presented in Composites 101 to
provide:
• a greater understanding of FRP composite materials and properties,
and
• options to manufacture composites
• General guidelines in design of FRP composites products
• Help answer the question – why composites.
Objectives of Session
3
September 21-24, 2020 / www.theCAMX.org
Outline
1. Fiber Reinforcements
2. Polymers (matrix)
3. Manufacturing / Product and Process Characteristics
4. Designing with Composites
5. Recycling Composites
4
September 21-24, 2020 / www.theCAMX.org
Composites 101 – An Overview
From the ACMA CCT Program, Composites defined as:
• “A combination of reinforcement fiber in a polymer resin matrix, whereas the reinforcement has an aspect ratio that enables the transfer of loads between fibers, and the fibers are chemically bonded to the resin matrix”.– A combination of fiber in a polymer matrix – A resin matrix reinforced with
a fiber• The reinforcement has an aspect ratio that enables the transfer of loads between fibers
– The fibers are long and narrow, and where they overlap the polymer matrix transfers loads to the adjacent fibers
• The fibers are chemically bonded to the resin matrix – There is adhesion between the fibers and matrix and the fibers do not move within their encapsulation when loaded
5
1. Fiber Reinforcements
6
September 21-24, 2020 / www.theCAMX.org
Constituent Components: FibersTypical Composite Reinforcing Fibers: Glass
• E-Glass (Alumina-calcium-borosilicate):
– General purpose fiber with good strength and high electrical resistivity
– Forms• Single end “direct draw” roving for fabric weaving, stitch-bonding, braiding, pultrusion, filament
winding– From very fine yarn for electrical circuit boards to heavy roving for industrial composites
• Multi-end “assembled” roving for chopped mat
– Nomenclature and composition outlined in ASTM D578
– Typically named after sizing type
– Select Products: • Hybon® 2026 (PPG/NEG), StarRov® (JM), 469L (CPIC), TD44C (Vetrotex)
• ECR-Glass (Calcium aluminosilicate):
– Boron oxide-free version of E-glass which increases acid corrosion resistance
– Produced in same forms as E-glass
– Select Products: • Advantex® (Owens Corning), E6CR™ 396 (Jushi)
7
September 21-24, 2020 / www.theCAMX.org
Constituent Components: FibersTypical Composite Reinforcing Fibers: Glass
• A-Glass (Soda lime silicate):
– Lower strength/durability fiber compared to E-glass, only in veil/mat format
– Select Products: • Surmat® 200 veil (Superior Composites Co.)
• H-Glass (Calcium aluminosilicate):
– Higher strength and modulus version of ECR-glass fiber
– Select Products: • Xstrand® H (Owens Corning)
• R-Glass (Calcium aluminosilicate and Basalt):
– Higher strength and modulus than H-glass fiber
– Select Products: • INNOFIBER® Hybon® XM (PPG/NEG)
• C-Glass (Calcium borosilicate):
– Used for highly corrosive acidic environments, usually only in nonwoven veil format
– Select Products: • C64 C-Veil (Owens Corning)
8
September 21-24, 2020 / www.theCAMX.org
Constituent Components: FibersTypical Composite Reinforcing Fibers: Glass
• AR-Glass (Alkali zirconium):
– Highly alkali resistant fiber used for cement and concrete reinforcement
– Select Products: • Cem-FIL® (Owens Corning)
• S-Glass (Magnesium aluminosilicate):
– Higher strength and modulus fiber than R-glass, also very good high temperature and corrosion resistance
– Select Products: • S-1 Glass™, S-2 Glass®, & S-3 Glass™ (AGY)
• Quartz (99.99% Pure silica):
– Highly expensive fiber with very low coefficient of thermal expansion (CTE) and superior electromagnetic properties (for radio frequency transparency – radomes)
– Select Products: • Astroquartz® (JPS) , Quartzel® (Saint-Gobain)
9
September 21-24, 2020 / www.theCAMX.org
Constituent Components: Fibers
10
September 21-24, 2020 / www.theCAMX.org
Constituent Components: Fibers
Typical Composite Reinforcing Fibers: PAN Based Carbon– The most widely available and utilized type is produced from a specially formulated
polyacrylonitrile (PAN) precursor fiber
• The PAN carbon fiber is generally classed in 3 different groups
according to modulus– Standard Modulus (SM) / High Strength (HS)
• Most widely used in industrial applications
• Most cost effective
– Intermediate Modulus (IM)• Best blend of strength/modulus,
• Typically used in aerospace/defense applications
– High Modulus (HM)• Highest stiffness, lowest CTE, highest conductivity, & lower strength than SM & IM versions,
highest cost,
• Typically used in space craft/satellites/sporting equipment
11
September 21-24, 2020 / www.theCAMX.org
Constituent Components: Fibers
Classification
Tensile Modulus* Tensile Strength*
Msi GPa ksi MPa
Standard Modulus/High Strength 33-37 230-255 500-725 3,450-5,000
Intermediate Modulus 40-45 275-310 600-925 4,130-6,370
High Modulus 45-87 310-600 275-700 1,890-4,900
*Note: Carbon fiber modulus, strength, and elongation to beak are ideal values produced via
impregnated strand testing and may not translate directly to the corresponding fabric/composite
properties due to fiber misalignment, resin compatibility, and damage during processing
12
September 21-24, 2020 / www.theCAMX.org
Constituent Components: FibersTypical Composite Reinforcing Fibers: PAN Based Carbon
Standard Modulus (SM) / High Strength (HS):
• Small (1K) to Large (60K) tow sizes available, aerospace to industrial grade
• Select Products:
– Toray: T300, T700S & Zoltek (Subsidiary): Panex® 35; Toho-Tenax: HTA40; UTS50, Mitsubishi
Chemical/Grafil: 34-700, TRH50; SGL: C T24, C T50; Hexcel: AS4, AS7; Solvay (Cytec): T-300
– Others: AKSA, Bluestar, Formosa, Hyosung, Dalian Xingke, GanSu HaoShi
Intermediate Modulus (IM):
• Smaller range of tow sizes (6K-24K), recent work on large tow industrial
versions (ORNL)
• Select Products:
– Toray: T800H, T1000G; Toho-Tenax: IMS40, IMS65; Mitsubishi Chemical/Grafil: MR40, MR
60H; Hexcel: IM7, IM10; Solvay (Cytec): T-650; Formosa: T-42
High Modulus (HM):
• Small range of tow sizes (3K-12K)
• Select Products:
– Toray: M40J, M60J; Toho-Tenax: UMS40, HMA35; Mitsubishi Chemical/Grafil: HR 40, HS 40;
Formosa: TC55
13
September 21-24, 2020 / www.theCAMX.org
Constituent Components: FibersTypical Composite Reinforcing Fibers: Pitch Based Carbon
• Precursor material is by-product of fossil fuel processing: – Coal & Petrol Tar (i.e. Pitch)
• Isotropic: Typically low modulus, used for thermal management applications
• Mesophase Pitch: (made by polymerizing isotropic pitch to a higher molecular weight)
– Highly aligned carbon chains along fiber axis provide extremely high modulus, thermal conductivity and are called “Ultra High Modulus” (UHM) carbon or graphite fiber
– 1K-16K tow sizes typically available
– There has been work on lower cost precursor (ref. CompositesWorld)
– Applications: aerospace, civil engineering (concrete strengthening), sports – golf shafts
• Select Products:– Mitsubishi Chemical: DIALEAD® K63712, K13C2U
– Nippon Graphite Fiber: GRANOC YSH-50A-10S, YS-80A-60S
Classification
Tensile Modulus* Tensile Strength*
Msi GPa ksi MPa
Ultra High Modulus 75-136 520-935 375-550 2,600-3,800
*Note: Carbon fiber modulus, strength, and elongation to beak are ideal values produced via impregnated strand testing and may not translate
directly to the corresponding fabric/composite properties due to fiber misalignment, resin compatibility, and damage during processing
14
September 21-24, 2020 / www.theCAMX.org
Constituent Components: Fibers
Typical Composite Reinforcing Fibers: Polymer Based
• Para-Aramid:
– Low density and high strength with high impact and fatigue resistance
– Fiber exhibits a “soft” failure mode in that it doesn’t shatter upon impact or flexing
– Has UV and moisture absorption issues
– For composites, use the “high modulus” versions: K49, K149, & T2200, low modulus for
ballistics (K29)
– Select Products:
• Kevlar® (Dupont) & Twaron® (Teijin)
15
September 21-24, 2020 / www.theCAMX.org
Constituent Components: FibersTypical Composite Reinforcing Fibers: Comparison
Tensile
Strength
Tensile
ModulusElongation Density Cost
ksi Msi % lb/in3
E-Glass 290 to 360 10 to 10.5 3 to 5 0.092 to 0.094 $
E-CR Glass 320 to 375 11.75 3 to 5 0.095 $
H-Glass 350 to 420 13.00 3 to 5 0.094 $$
R-Glass 440 to 493 13.00 5.35 0.092 $$$
S-Glass 495 to 555 13.25 5.50 0.089 $$$$
Basalt (R-Gl.) 392 to 464 12.34 to 13.79 3 to 5 0.096 $$$$
SM Carbon 500-725 34 to 37 1.5 to 2.0 0.065 $$$$$
IM Carbon 600 to 925 40 to 45 1.5 to 2.2 0.065 $$$$$$
HM Carbon 275 to 700 45 to 87 ~1.0 0.063 to 0.069 $$$$$$$
UHM Carbon 380 to 550 114 to 135 >1.0 0.070 to 0.078 $$$$$$$$
Aramid (K49) 525 16.30 2.4 0.052 $$$$$
Aramid (K149) 501 26.00 1.9 0.053 $$$$$$
FIBER PROPERTIES (IMPREGNATED STRAND)
Ara
mid
Fiber
Type
Gla
ss
Carb
on
16
September 21-24, 2020 / www.theCAMX.org
Constituent Components: FibersTypical Composite Reinforcing Fibers: Polymer Based
• Polypropylene: Innegra™ (Innegra Technologies)
– Extremely (< 1.0 g/cc) low density polyolefin fiber with very good dynamic response characteristics
– Fairly low mechanical properties, but a cost-effective alternative to para-aramid / UHMWPE / PBO/LCP fibers with
better matrix resin bonding properties
– Works well as a hybrid with more brittle fiber (i.e. carbon) for increased ductility and impact resistance
• Ultra High Molecular Weight Polyethylene - UHMWPE: Spectra® (Honeywell) & Dyneema® (DSM)
– Very low-density polyolefin fiber made of extremely long polymer chains of polyethylene
– High resistance to chemicals, water & ultraviolet light, 40% stronger than aramid fiber
– Capable of withstanding high-load and strain-rates
– Need special fiber surface modifications to properly bond to composite matrix resins, can have creep issues
• Polybenzoxazole - PBO: Zylon® (Toyobo)
– Comparable to slightly higher tensile properties compared to UHMPE fibers, but with higher heat resistance
– The fiber is almost twice as strong as aramid fibers, about 10 times stronger than steel
– Also needs surface treatments for proper use with composite resins
• Liquid Crystal Polymer - LCP: Vectran™ (Kuraray)
– Excellent creep and abrasion resistance, minimal moisture absorption, chemical resistance, Low CTE, high dielectric
strength, & high impact strength
– Same bonding issues as with UHMWPE and PBO fibers.
– Outstanding strength at extreme temperatures, resistance to virtually all chemicals, weathering, radiation and burning
– Pound for pound, Vectran™ is 5x stronger than steel, 10x stronger than aluminum
17
September 21-24, 2020 / www.theCAMX.org
Constituent Components: FibersTypical Composite Reinforcing Fibers: Other/Special
• Ceramic:
– For high temperature applications up to 2372°F (1300°C)
– Used in ceramic matrix and metal matrix composites
– SiC (Silicon Carbide):
• High strength properties up to 2192°F (1200°C), wettability for metals, low electrical
conductivity, high heat resistance, and corrosion resistance/chemical stability
• Select Products: SCS-6 (Specialty Materials, Inc.), Tyranno Fiber® (UBE Industries)
– Oxide/Alumina:
• High chemical stability, high melting point, high modulus, and good strength at high
temperature
• Select Products: Nextel™312, Nextel™440 (3M)
• Boron:
– Elemental boron is deposited on a fine tungsten wire substrate and produced in
diameters of 4mil up to 11mil.
– Known for high compression properties, but low conformability
• Select Products: Boron fiber (Specialty Materials, Inc.)
Typical SiC / Alumina Fiber Application
SEM Photo of Boron Fiber
18
September 21-24, 2020 / www.theCAMX.org
Constituent Components: FibersTypical Composite Reinforcing Fibers: Other/Special
Natural: using these fibers revolve around environmental sustainability
• Typical Example Types:
✓ bast fibers such as jute, flax, hemp, ramie, and kenaf;
✓ leaf fibers such as banana, sisal, agave, and pineapple;
✓ seed fibers such as coir, cotton, and kapok;
✓ core fibers such as kenaf, hemp, and jute;
✓ grass and reed fibers such as wheat, corn, rice, and bamboo
• Advantages:
– Low density, are biodegradable, are derived from renewable resources, have a small carbon footprint, provide good thermal
and acoustical insulation, good vibration damping, moderate mechanical properties and high specific properties
• Challenges:
– Still have matrix-fiber interface issues – hydrophilic nature makes them incompatible with existing hydrophobic resin systems
used in the industry
– Very low load transfer efficiency
– There are few in the composites industry with enough experience to work with them confidently
– Mostly derived from plants grown in developing countries such as Bangladesh, India, Sri Lanka, also China
• Select Products: Most natural fiber reinforcements are used in nonwoven form
– Increasing use in automotive interior panels
– Flax: Biotex (Composites Evolution)
– Cellulose: BioMid® (GS Consulting)
19
September 21-24, 2020 / www.theCAMX.org
Constituent Components: FibersTypical Composite Reinforcing Fibers: Other/Special
Graphene: • A single, 2D layer of carbon atoms, tightly packed in a hexagonal lattice structure
• Graphite is made up of millions of layers of Graphene– 1 mm of graphite is ~3 million of layers of Graphene thick
– Graphite is mixed with clay to make pencil “lead”
• Properties– It is the thinnest, strongest material yet discovered and the most efficient conductor of both heat and electricity currently
available
– Size: Single-Wall Carbon Nanotubes (SWCNT) = ~1-2 nm, DNA = 2.5 nm
• Perspective: COVID-19 Virus Diameter is 350-400 x The Thickness of Graphene!
– Strength: 300 times the tensile strength of steel
– Performance: 20 times the thermal conductivity of copper, 5-6 times of diamond
– Electrical: Can be a Semiconductor, a Superconductor or a perfect Insulator depending on how it is used
– Appearance: Nearly transparent, at one layer, Graphene absorbs ~1.7% of light
• How is Graphene made?– Mechanical Exfoliation
– Chemical Vapor deposition (CVD)
• Where has Graphene been used– Clothing, golf balls, ink, tires, concrete, asphalt, fire retardant paint, coatings
– Automotive – engine compartment, sound-attenuating foam for 2019 F-150 and F-250 Pickup, Lincoln Navigator and Mustang
20
2. Polymers (Matrix)
21
September 21-24, 2020 / www.theCAMX.org
Constituent Components: MatrixTypical Composite Thermoset Matrices
– Unsaturated Polyester (UPR)
• Accounts for approximately 75% of matrix resins used for composites molding
• Comprises isophthalic, orthophthalic, DCPD, and terephthalic based systems
• Polymer comes mixed with a reactive diluent (typically styrene)
– Vinyl Ester
• Formulated by reacting an epoxy (Bisphenol-A or Novolac) backbone with methacrylic acid, forming a polymer that has
characteristics of both UPR and epoxy
• Superior corrosion resistance, low water permeability, and good fatigue resistance
– Epoxy
• Most widely used matrix resin in high performance applications
• Superior mechanical properties, resistance to corrosive environments, superior electrical properties, and elevated
temperature performance
– Urethane/Urea
• Highly reactive 2-part matrix resin producing high flexibility and toughness
• Moisture sensitive cure and components can be a health hazard (isocyanates)
– Phenolic
• Low structural properties, but very good fire resistance
• Condensation reaction (produces water) which can lead to porosity in the laminate when manufactured
22
September 21-24, 2020 / www.theCAMX.org
Constituent Components: Matrix
Typical Composite Thermoset Matrices
• High Temperature– BMI & Polyimide:
• High temperature resistance (service temp up to
260°C), chemical and radiation stability
– Cyanate Ester: • High Tg (300°C), low outgassing, and low dielectric
constant and loss
– Benzoxazine: • Excellent stiffness and high-temperature
performance, low resin shrinkage for improved
dimensional stability
23
September 21-24, 2020 / www.theCAMX.org
Constituent Components: Matrix
Typical Composite Thermoset Matrices
• Hybrids– Urethane Ester:
• Excellent toughness, adhesion, water resistance, and speed of cure
• Select Products: – Xycon® 047-8023 (Polynt)
– Urethane Acrylate: • Similar in properties to the urethane ester, and has a Tg around 280°C
• Select Products: – Crestapol® 1250LV (Scott Bader)
– Core Shell Rubber-Modified Vinyl Ester: • Nano-particle enhance technology that significantly improves the impact and energy
absorbing properties of a polymer matrix
• Select Products: – 781-6010 (Polynt)
24
September 21-24, 2020 / www.theCAMX.org
Constituent Components: MatrixTypical Composite Thermoplastic Matrices
• Commodity– Polypropylene (PP): Low cost polymer, low melting point, excellent moisture
resistance
– Polyester (PET) : Low cost polymer, high chemical resistance, low moisture regain
– Polyamide 6 (Nylon 6): Good price/performance ratio, good chemical resistance, high strength
– Polyamide 12 (Nylon 12): Lower moisture regain and lower melting point than Nylon 6, good resistance to shock and chemicals
• Engineered/High Temperature– Polyetherimide - PEI: High thermal stability, low flame and smoke, similar to PEEK
but lower temperature resistance and impact strength
– Polyphenylene sulfide - PPS: Chemical resistance, flame retardancy, dimensional stability, low moisture absorption
– Polyetheretherketone - PEEK: Thermal stability, abrasion resistance, superior chemical resistance, flame retardancy, high stiffness and low density
– Polyaryletherketone - PAEK: Highly fire-resistant, has good chemical resistance, and can be used for high temperature applications
25
3. Manufacturing / Process and
Product Characteristics
26
September 21-24, 2020 / www.theCAMX.org
The World of Manufacturing
• Teamwork is important
– Design Engineer
– Stress Engineer
– Manufacturing Engineer
– Materials Engineer
– Tool Designer/Tool Engineer
– Technicians
– Inspection/Quality
27
September 21-24, 2020 / www.theCAMX.org
Process Selection Considerations
28
• Surface complexity expense of the tool
• Performance complexity of laminate fiber architecture
• Surface appearance secondary operations needed
• Size of the part hand vs machine
• Production rate hand vs machine
• Total production volume hand vs machine
• Economic target (limit) hand vs machine
– Part cost
• materials, tooling, equipment, labor)
September 21-24, 2020 / www.theCAMX.org
Categories of Manufacturing Processes
• Open Molding
– One side is a tool surface, opposite side there is no tool surface
• Closed Molding
– There is a tool surface on both sides
• Types of Manufacturing Processes
– Common or Basic
– Advanced
29
September 21-24, 2020 / www.theCAMX.org
Typical Open Molding Processes
• Casting (Cast Polymer Molding)
• Centrifugal Casting
• Filament Winding– Wet winding
– Prepreg winding
• Hand Lay-up– Wet Lay-up vacuum bagging
– Prepreg Lay-up vacuum bagging (autoclave molding)
• Spray-up
30
September 21-24, 2020 / www.theCAMX.org
Typical Closed Molding Processes
• Compression Molding– Wet Compression Molding (WCM) (also known as liquid molding or
cold molding)
– Sheet Molding Compound (SMC)
– Bulk Molding Compound (BMC)
– Dynamic Fluid Compression Molding
• Continuous Lamination
• Cured In-Place Pipe (CIPP)
• Extrusion
31
September 21-24, 2020 / www.theCAMX.org
Typical Closed Molding Processes
• Injection Molding– Bulk Molding Compound (BMC)
– Hybrid injection-molding/thermoforming
• Pultrusion
• Reinforced Reaction Injection Molding (RRIM)– RIM Overmolding
• Resin Transfer Molding (RTM)– Light RTM
• Vacuum Assisted RTM (VA-RTM)– Resin Infusion
– Vacuum Infusion Processing (VIP)
– High Pressure – RTM (HP-RTM)
32
September 21-24, 2020 / www.theCAMX.org
Hand Lay-Up
33
Just about anything, large or small
September 21-24, 2020 / www.theCAMX.org
Vacuum Vacuum
Wet Lay-up Vacuum Bagging
3434
Just about anything, large or small
September 21-24, 2020 / www.theCAMX.org
Spray-Up Process
35
Boats, tubs, showers, sinks, panels
September 21-24, 2020 / www.theCAMX.org
PROCESS Characteristics
Hand Lay-up / Spray-up
• MAX SIZE: Unlimited
• PART GEOMETRY: Simple - Complex
• PRODUCTION VOLUME: Low - Med
• CYCLE TIME: Slow
• SURFACE FINISH: Good - Excellent
• TOOLING COST: Low
• EQUIPMENT COST: Low
36
September 21-24, 2020 / www.theCAMX.org
PRODUCT Characteristics
Hand Lay-up / Spray-up
• Small to large parts achievable
• Cost effective solution
• Prototype to production parts
• Any shape, size, surface texture possible
• Laminates, sandwich panel construction
• Complicated lay-up of lamina possible
• Inexpensive to expensive materials could be used
• Can be automated with spray-up
• Highly operator dependent – potential for wide variations in quality
37
September 21-24, 2020 / www.theCAMX.org
Filament Winding
Resin
Utility poles, columns, pipe, missile casing, tanks, stack liners
38
September 21-24, 2020 / www.theCAMX.org
PROCESS Characteristics
Filament Winding
• MAX SIZE: <65’ Diameter
• PART GEOMETRY: Simple
• PRODUCTION VOLUME: Low - Med
• CYCLE TIME: Low - Med
• SURFACE FINISH: Inside - Good/Excellent, Outside – Fair**
• TOOLING COST: Med - High
• EQUIPMENT COST: Med - High
**depends on material (wet vs prepreg)
39
September 21-24, 2020 / www.theCAMX.org
PRODUCT Characteristics
Filament Winding
• Body of revolution
• Controlled strength
• Directional strength
• Computer controlled fiber placement
• Low labor
• Products can be made in the factory or out in the field
• Emission controls required (except pre-preg)
40
September 21-24, 2020 / www.theCAMX.org
Centrifugal Casting
• Centrifugal Casting is used for making cylindrical, hollow shapes such as tanks, pipes and poles.
• Chopped strand mat is placed into a hollow, cylindrical mold, or continuous roving is chopped and directed onto the inside walls of the mold.
• Resin is applied to the inside of the rotating mold
Source: CompositesLab.org
41
September 21-24, 2020 / www.theCAMX.org
PROCESS Characteristics
Centrifugal Casting
• MAX SIZE: <15’ Diameter
• PART GEOMETRY: Simple
• PRODUCTION VOLUME: Med
• CYCLE TIME: Low - Med
• SURFACE FINISH: Good
• TOOLING COST: Med
• EQUIPMENT COST: Med
42
September 21-24, 2020 / www.theCAMX.org
PRODUCT Characteristics
Centrifugal Casting
• Body of revolution
• Outside surface is finished (tool side)
• Limited part size (mold and machine)
43
September 21-24, 2020 / www.theCAMX.org
SMC
Compression Molding
44
September 21-24, 2020 / www.theCAMX.org
PROCESS Characteristics
Compression Molding
• MAX SIZE: Limited by Press Machine
• PART GEOMETRY: Simple - Complex
• PRODUCTION VOLUME: High
• CYCLE TIME: Fast
• SURFACE FINISH: Good - Excellent
• TOOLING COST: High
• EQUIPMENT COST: High
45
September 21-24, 2020 / www.theCAMX.org
PRODUCT Characteristics
Compression Molding
• High Volume Output
• Inside & Outside has finished “tool” surface
• Low per part cost in high volume manufacturing
• Low finishing cost
• Close part tolerances are achievable
• Molded-in texture and color possible
• Low scrap materials – supports sustainability
46
September 21-24, 2020 / www.theCAMX.org
Compression Molding
• Alternative Molding Materials:
– Sheet Molding Compound (SMC)
– Bulk Molding Compound (BMC)
– Wet layup and preform system
– Reinforced thermoplastic sheet goods
47
September 21-24, 2020 / www.theCAMX.org
SMC
• PROCESS Characteristics – High volume productions
– High equipment and mold costs
– Low labor costs
– Engineered material systems
– Process reproducible
• Advantages– Directly formed to net shape
– Integral ribs and bosses
– Variable wall thickness possible
48
Source: IDI Composites International
SMC - mixture of polymer resin, inert
fillers, fiber reinforcement, catalysts,
pigments and stabilizers, release agents,
and thickeners and possesses strong
dielectric properties
September 21-24, 2020 / www.theCAMX.org
BMC
• PROCESS Characteristics– High equipment and mold cost
– Low labor
– High material efficiency
– Highly reproducible
• Advantages– Can mold highly complex shapes
– Can be used in both compression and injection molding
– Low cost alternative
49
BMC - Is a thermoset resin blend of
various inert fillers, fiber reinforcement,
catalysts, stabilizers, and pigments that
form a viscous, 'puttylike' injection
molding compound. It is often highly filled
and reinforced with short fibers.
September 21-24, 2020 / www.theCAMX.org
Pultrusion
Resin
Heated DieCured
Profile
Bridge decks, rebar, structural profiles, sheet piling, dowel bars,
utility poles & cross arms, grating, cable trays, marine pier decks
50
September 21-24, 2020 / www.theCAMX.org
PROCESS Characteristics
Pultrusion
• MAX SIZE: Length: Unlimited, Width: Tool Dependent
• PART GEOMETRY: Simple - Complex
• PRODUCTION VOLUME: Med - High
• CYCLE TIME: Med
• SURFACE FINISH: Good
• TOOLING COST: Med - High
• EQUIPMENT COST: Med - High
51
September 21-24, 2020 / www.theCAMX.org
PRODUCT Characteristics
Pultrusion
• Constant cross section shapes
• Continuous lengths
• Highly oriented strengths (longitudinal direction)
• Complex profiles possible
• Hybrid reinforcements can be used
• **shapes can be curved
52
September 21-24, 2020 / www.theCAMX.org
Resin Transfer Molding
Resin Injection Unit
Vent Vent
53
September 21-24, 2020 / www.theCAMX.org
Resin Transfer Molding
• LRTM: “Light Resin Transfer Molding”
– Low pressure thermoset resin injection w/ reinforcement
loading between matched low cost tooling
• RTM: “Resin Transfer Molding”
– Higher pressure thermoset resin injection w/
reinforcement loading between matched tooling
54
September 21-24, 2020 / www.theCAMX.org
PROCESS Characteristics
Resin Transfer Molding
• MAX SIZE: 6’ x 6’
• PART GEOMETRY: Complex
• PRODUCTION VOLUME: Med
• CYCLE TIME: Med
• SURFACE FINISH: Good - Excellent
• TOOLING COST: Med
• EQUIPMENT COST: Med
55
September 21-24, 2020 / www.theCAMX.org
PRODUCT Characteristics
Resin Transfer Molding
• Two controlled tool surfaces
• Molded in finishes
• Molded in stiffeners and connection points
• Large part capable, depends on tool size
56
September 21-24, 2020 / www.theCAMX.org
Vacuum Vacuum
Vacuum Infusion Processing
VIP
Resin
Boats, marine piling, bridge decks,
architectural products,
➢ VARTM
➢ Resin Infusion
➢ SCRIMP™
57
September 21-24, 2020 / www.theCAMX.org
PROCESS Characteristics
VIP (VARTM)
• MAX SIZE: Unlimited
• PART GEOMETRY: Simple - Complex
• PRODUCTION VOLUME: Low - Med
• CYCLE TIME: Slow-Fast (size dependent)
• SURFACE FINISH: Good
• TOOLING COST: Low
• EQUIPMENT COST: Low
58
September 21-24, 2020 / www.theCAMX.org
PRODUCT Characteristics
VIP (VARTM)
• No voids
• High fiber volume (65%)
• High strength applications
• Large part size– Flat
– Curve or rounded
– Long (limited by shipping)
• Fabrication possible in the field, although controlled factory conditions are preferred
59
September 21-24, 2020 / www.theCAMX.org
Advanced Manufacturing Processes
• Autoclave Molding– Prepreg
• Co-Curing
• Automated Tape Placement (ATP)
• Automated Fiber Placement (AFP)
• Out of Autoclave Processing– Vacuum Bag Molding
– Reusable Bag Molding (RSBM)
• Additive Manufacturing (AM)
60
September 21-24, 2020 / www.theCAMX.org
Autoclave Molding
Pre-Preg Vacuum Bagging
61
Vacuum Vacuum
61
September 21-24, 2020 / www.theCAMX.org
Automated Fiber Placement
Source: Electroimpact.com
62
September 21-24, 2020 / www.theCAMX.org
Automated Tape Placement
Source: Sciencedirect.com
Source: CompositesWorld.com
63
September 21-24, 2020 / www.theCAMX.org
Additive Manufacturing
• Types of Additive Manufacturing Processes– 3-D Printing
• Reactive Additive Manufacturing (RAM) new
– Digital Light Processing (DLP)
– Fused Deposition Modeling (FDM)
– Fused Filament Fabrication (FFF)
– Selective Laser Sintering (SLS)
– Stereolithography (SLA)
• BAAM – Big Area Additive Manufacturing
64
September 21-24, 2020 / www.theCAMX.org
PROCESS Characteristics
Advanced Manufacturing Processes
• MAX SIZE: Small - Large
• PART GEOMETRY: Simple - Complex
• PRODUCTION VOLUME: Low - Med
• CYCLE TIME: Slow-Med (size dependent)
• SURFACE FINISH: Good
• TOOLING COST: High
• EQUIPMENT COST: High
65
September 21-24, 2020 / www.theCAMX.org
PRODUCT Characteristics
Advanced Manufacturing Processes
• Prototype to full production
• Long time to qualify materials
• Can expect no voids in laminate – process dependent
• High fiber volume (+65%)
• High Strength Applications
• Large part size– Flat
– Curved or rounded
– Long (limited by shipping)
– Complex contour
66
4. Designing with Composites
67
September 21-24, 2020 / www.theCAMX.org
Thinking Composites
• Composites are simply another material system.
• They are not the only solution for all product applications.
• Each individual material has a unique set of attributes that
determine whether that material is suitable.
• A composite design should not imitate both form and
function of an existing design in another material if
composites are to offer value.
6868
September 21-24, 2020 / www.theCAMX.org
Composites Features
❖ High Strength
❖ Corrosion resistance
❖ Light weight
❖ Electrical properties
❖ Thermal properties
❖ Non-magnetic
❖ Dimensional stability
❖ Part consolidation
❖ Design flexibility
❖ Unique shapes
❖ Damage tolerance
❖ Radar transparency
❖ Tailored surface
❖ Long-term durability
❖ FDA compliant
69
September 21-24, 2020 / www.theCAMX.org
Part Design with Composites:
Short Fiber Composites
• Why are short fiber composites needed?
– Low cost/high volume production• Both for thermoplastic (milled fiber injection molding) & thermoset (SMC)
– Ease of fabricating complex part geometries• Continuous fibers can be difficult to conform and stretch and can become
distorted and damaged
– Isotropic behavior• Randomly oriented short fiber composites give isotropic behavior response,
which makes them easier to analyze
70
September 21-24, 2020 / www.theCAMX.org
Part Design with Composites:
Short Fiber Composite Material Forms
• Milled Fiber: – 3 to 60mil long fibers– Reinforces body fillers, casting material and injection molded thermoplastics to increase
strength/stiffness and dimensional stability by reducing shrinkage– Increase electrical/thermal properties (milled carbon fiber)
• LFRT: – “Long Fiber Reinforced Thermoplastic” – with fibers up to 0.5in in length– Mid-range material with properties between milled fiber and chopped fiber
thermoplastic composites• Longer fibers allow for higher fiber content composites, driving up mechanical performance
• Chopped Fiber: – Composites typically having 2-4in long fibers– Majority of consumer good “fiberglass” (bathtubs, body panels, etc.)
• Most LRTM and RTM process applications w/permeable core material
71
September 21-24, 2020 / www.theCAMX.org
Part Design with Composites:
Short Fiber Composites
72
September 21-24, 2020 / www.theCAMX.org
Part Design with Composites:
Continuous Fiber Composites Material Forms• Woven fabrics
Plain Weave
Basket Weave
4-Harness Satin
Weave (Crowfoot)
73
September 21-24, 2020 / www.theCAMX.org
Part Design with Composites:
Continuous Fiber Composites Material Forms• Woven fabrics
8-Harness Satin
WeaveLeno Weave2x2 Twill Weave
74
September 21-24, 2020 / www.theCAMX.org
Part Design with Composites:
Continuous Fiber Composites Material Forms
• Braids
– Similar to wovens, but can be used to make cylindrical and
other cross sectional shape preforms
– Can be slit to create broadgood fabrics
0/60/-60 Braided
Broadgood Braided Beam75
September 21-24, 2020 / www.theCAMX.org
Part Design with Composites:
Continuous Fiber Composites Material Forms
• NCF – Non-Crimp Fabrics
– Up to 30% higher in-plane strength compared to equivalent areal
weight woven reinforcements
• No fiber crimp = No stress concentrations, higher fiber property translation
• Lower amount of resin required for complete saturation
• Greater stability, less skewing during processing
76
September 21-24, 2020 / www.theCAMX.org
Part Design with Composites:
Continuous Fiber Composites Material Forms
• NCF – Non-Crimp Fabrics– Typically available constructions
– Up to 4 plies/layers per one-pass fabric
– Bias angle vary from 300 to 900
– ±450, ±600, & 900 are most common
– Standard constructions
• Unidirectional (00 & 900),
• Biaxial (00/900 & +450/-450),
• Triaxial (00/+450/-450 & +450/900/-450), &
• Quadriaxial (00/+450/900/-450)
77
September 21-24, 2020 / www.theCAMX.org
Part Design with Composites:
Continuous Fiber Composites Material Forms• Other Forms
– 3D Wovens
• Non-Crimp Woven with Z-axis fiber
• 3D preforms
– Prepreg
• Unidirectional – Narrow tapes to wide widths
• Fabric – Wovens, braids, NCF
Carbon Fiber Uni Prepreg Tape
3D Woven Preform
Non-Crimp Fabric w/Z-Axis Fiber
78
September 21-24, 2020 / www.theCAMX.org
FRP Composites
Thermoset Composites
• Typical Thermoset Composites– E-Glass/UPR:
• Most common for industrial composites
– ECR-Glass/VE: • Used for highly corrosive applications (rebar, scrubbers, jet bubble reactors, etc.)
– SM Carbon/Epoxy: • The standard for high performance composites in aerospace, sporting goods, and
COPV’s
– SM Carbon/VE: • Gaining use in marine and industrial composites. Needs to be evaluated per
application
79
September 21-24, 2020 / www.theCAMX.org
FRP Composites
Thermoset Composites• Typical Thermoset Composites
Tensile
Strength
Tensile
ModulusElongation Density
ksi Msi % lb/ft3
E-Glass/VE 185 5.87 3.15 121
E-CR Glass/VE 197 6.67 2.95 123
H-Glass/VE 218 7.35 2.97 123
R-Glass/VE 264 7.35 3.59 120
S-Glass/VE 297 7.49 3.97 117
Basalt/VE 242 7.39 3.27 124
SM Carbon/VE 340 18.90 1.80 95
IM Carbon/VE 423 23.30 1.82 95
K49/VE 295 9.17 3.22 82
K149/VE 280 14.50 1.93 83
Carb
on
Ara
mid
COMPOSITE PROPERTIES (UNIDIRECTIONAL) Vf = 55%
Composite
Type
Gla
ss
Tensile
Strength
Tensile
ModulusElongation Density
ksi Msi % lb/ft3
E-Glass/VE 69 4.18 1.65 121
E-CR Glass/VE 76 4.63 1.64 122
H-Glass/VE 83 5.04 1.65 122
R-Glass/VE 83 5.07 1.64 120
S-Glass/VE 86 5.21 1.65 118
Basalt/VE 83 5.04 1.65 123
SM Carbon/VE 219 13.37 1.64 103
IM Carbon/VE 268 16.36 1.64 103
K49/VE 117 7.13 1.64 93
K149/VE 180 10.98 1.64 93Ara
mid
COMPOSITE PROPERTIES (BIAXIAL 60%/40%) Vf = 55%
Composite
Type
Gla
ss
Carb
on
80
September 21-24, 2020 / www.theCAMX.org
Polymer Matrix Composites (PMC):
Thermoplastic Composites
• Typical Thermoplastic Composites
– E-Glass/PP:
• Commodity grade composite for industrial uses
• Commingled continuous fiber & LFRT
– E-Glass/Nylon:
• Higher performance and cost over E-glass/PP
– SM Carbon/PPS (Polyphenylene sulfide):
• High temperature & mechanical performance
– SM Carbon/PEEK:
• Similar use to SM carbon/PPS, can be comparatively
difficult to process
Carbon / PEEK Aircraft Door Fitting
Jushi Compofil™ E-Glass/PP Commingled Fiber
Woven Fabric
81
September 21-24, 2020 / www.theCAMX.org
Property Comparison of FRP
with Legacy Materials: Advantages
• High Specific Strength & Stiffness
• Inherently Corrosion Resistant
• High Durability
• Flexibility: Design & Production
82
September 21-24, 2020 / www.theCAMX.org
Property Comparison of FRP
with Legacy Materials: Disadvantages
• Lower Direct Stiffness– Steel: 30Msi,
– Aluminum: 20Msi
• Flammability / Temperature
• Moisture
• Cost
• Availability
• Acceptance– Learning Curve
83
5. Recycling Composites
84
September 21-24, 2020 / www.theCAMX.org
Recycling Composites• Can Composites be recycled – Yes!
– Composites are strong, durable, and non-homogenous which make them inherently difficult
to recycle
• Opportunities to recycle:
– In-process manufacturing scrap
– End-of-Life service scrap
• Thermoset Composite materials can be recycled or recovered through many processes
– Mechanical grinding,
– Thermal (pyrolysis, fluidized bed),
– Thermo-chemical (solvolysis),
– Electro-mechanical (high voltage pulse fragmentation)
– Or combinations of these
– There are advantages and disadvantages of each
• Thermoplastic Composite materials can be shredded and recycled by melting, but the supply
chain is limited
85
September 21-24, 2020 / www.theCAMX.org
Recycling Composites• Business Proposition
– Glass fiber composites is all about volume
– Carbon fiber composites is all about value
– Growing supply chain of companies that recycle composites
– Markets exploring composites recycling include wind energy (blades), aerospace(manufacturing scrap and plane components), automotive (car components), marine (boats)
• Cement co-processing, also known as the cement kiln route, is a main technology for recycling composite scrap
• Different global regions are more advanced in technology and applying recycled materials than others, but there is general global industry collaboration
• What is needed:
– Establishment of a recycling supply chain to collect, sort, process and deliver composites scrap support the cement kiln, grinding, pyrolysis, and other routes.
– Market pull for recycled composite products
– Standardization of recycling composites process, selection, and use
– End-user qualification of recycled composite parts
– The Composites Industry needs to think and design for sustainability!
86
September 21-24, 2020 / www.theCAMX.org
Acknowledgements
• Special thanks to the following people who contributed information to this presentation:
• Trevor Gundberg, P.E., Vectorply Corporation
• Andrew Pokelwaldt, CCT-I, ACMA
• Steve Rogers, EmergenTek, LLC
• Dan Coughlin, ACMA
87
September 21-24, 2020 / www.theCAMX.org
Thank you!
John P. Busel, F.ACI, HoF.ACMA
VP, Composites Growth Initiative
American Composites Manufacturers Association
(914) 961-8007
88