Structural Composite Materials

Transcription

1 Structural Composite Materials F.C. Campbell The Materials Information Society ASM International Materials Park, Ohio

2 Contents Preface About the Author xi xv Chapter 1 Introduction to Composite Materials Isotropic, Anisotropic, and Orthotropic Materials Laminates Fundamental Property Relationships Composites versus Metallics Advantages and Disadvantages of Composite Materials Applications 18 Chapter 2 Fibers and Reinforcements Fiber Terminology Strength of Fibers Glass Fibers Aramid Fibers Ultra-High Molecular Weight Polyethylene Fibers Carbon and Graphite Fibers Woven Fabrics Reinforced Mats Chopped Fibers Prepreg Manufacturing 52 Chapter 3 Matrix Resin Systems Thermosets Polyester Resins Epoxy Resins Bismaleimide Resins Cyanate Ester Resins Polyimide Resins Phenolic Resins Toughened Thermosets Thermoplastics Thermoplastic Composite Matrices Thermoplastic Composite Product Forms Quality Control Methods Chemical Testing Rheological Testing Thermal Analysis Glass Transition Temperature Summary 99

3 vi / Contents Chapter 4 Fabrication Tooling General Considerations Thermal Management Tool Fabrication 111 Chapter 5 Thermoset Composite Fabrication Processes Lay-up Processes WetLay-Up Prepreg Lay-Up Manual Lay-Up Flat Ply Collation and Vacuum Forming Roll or Tape Wrapping Automated Methods Vacuum Bagging Curing Low-Temperature Curing/Vacuum Bag Systems Filament Winding Liquid Molding Preform Technology Resin Injection Priform Process RTM Curing RTM Tooling RTM Defects Vacuum-Assisted Resin Transfer Molding Resin Film Infusion Pultrusion 175 Chapter 6 Thermoplastic Composite Fabrication Processes Thermoplastic Consolidation Thermoforming Thermoplastic Joining 192 Chapter 7 Processing Science of Polymer Matrix Composites Kinetics Viscosity Heat Transfer Resin Flow Hydrostatic Resin Pressure Studies Resin Flow Modeling Voids and Porosity Condensation-Curing Systems Residual Curing Stresses Cure Monitoring Techniques 232 Chapter 8 Adhesive Bonding Theory of Adhesion Surface Preparation Composite Surface Preparation Aluminum Surface Preparation Titanium Surface Preparation Aluminum and Titanium Primers Epoxy Adhesives Two-Part Room-Temperature Curing Epoxy Liquid and Paste Adhesives Epoxy Film Adhesives 247

4 Contents / vii 8.4 Bonding Procedures PrekittingofAdherends Prellt Evaluation Adhesive Application Bondline Thickness Control Bonding 252 Chapter 9 Sandwich and Integral Cocured Structure Sandwich Structure Honeycomb Core Sandwich Structure Honeycomb Processing Cocured Honeycomb Assemblies Foam Cores Syntactic Core Integrally Cocured Unitized Structure 273 Chapter 10 Discontinuous-Fiber Composites Fiber Length and Orientation Discontinuous-Fiber Composite Mechanics Fabrication Methods Spray-Up Compression Molding Thermoset Compression Molding Thermoplastic Compression Molding Structural Reaction Injection Molding Injection Molding Thermoplastic Injection Molding Thermoset Injection Molding 304 Chapter 11 Machining and Assembly Trimming and Machining Operations General Assembly Considerations Hole Preparation Manual Drilling Power Feed Drilling Automated Drilling Drill Bit Geometries Reaming Countersinking Fastener Selection and Installation Special Considerations for Composite Joints Solid Rivets Pin and Collar Fasteners Bolts and Nuts Blind Fasteners Interference-Fit Fasteners Sealing and Painting 329 Chapter 12 Nondestructive Inspection Visual Inspection Ultrasonic Inspection Portable Equipment Radiographic Inspection Thermographic Inspection 345

5 viii / Contents Chapter 13 Mechanical Property Test Methods Specimen Preparation Flexure Testing Tension Testing Compression Testing Shear Testing Open-Hole Tension and Compression Bolt Bearing Strength Flatwise Tension Test Compression Strength After Impact Fracture Toughness Testing Adhesive Shear Testing Adhesive Peel Testing Honeycomb Flatwise Tension Environmental Conditioning Data Analysis 369 Chapter 14 Composite Mechanical Properties Glass Fiber Composites Aramid Fiber Composites Carbon Fiber Composites Fatigue Delaminations and Impact Resistance Effects of Defects Voids and Porosity Fiber Distortion Fastener Hole Defects 398 Chapter 15 Environmental Degradation Moisture Absorption Fluids Ultraviolet Radiation and Erosion Lightning Strikes Thermo-Oxidative Stability Heat Damage Flammability 417 Chapter 16 Structural Analysis Lamina or Ply Fundamentals Stress-Strain Relationships for a Single Ply Loaded Parallel to the Material Axes (9 = 0 or 90 ) Stress-Strain Relationships for a Single Ply Loaded Off-Axis to the Material Axes (0 * 0 or 90 ) Laminates and Laminate Notations Laminate Analysis Classical Lamination Theory Interlaminar Free-Edge Stresses Failure Theories Concluding Remarks 446 Chapter 17 Structural Joints Bolted and Bonded Mechanically Fastened Joints Mechanically Fastened Joint Analysis Single-Hole Bolted Composite Joints Multirow Bolted Composite Joints Adhesive Bonding 463

6 Contents / ix 17.6 Bonded Joint Design Adhesive Shear Stress-Strain Bonded Joint Design Considerations Stepped-Lap Adhesively Bonded Joints Bonded-Bolted Joints 481 Chapter 18 Design and Certification Considerations Material Selection Fiber Selection Product Form Selection Discontinuous-Fiber Product Forms Continuous-Fiber Product Forms Matrix Selection Fabrication Process Selection Discontinuous-Fiber Processes Continuous-Fiber Processes Trade Studies Building Block Approach Design Allowables Design Guidelines Damage Tolerance Considerations Environmental Sensitivity Considerations 512 Chapter 19 Repair Fill Repairs Injection Repairs Bolted Repairs Bonded Repairs Metallic Details and Metal-Bonded Assemblies 533 Chapter 20 Metal Matrix Composites Aluminum Matrix Composites Discontinuous Composite Processing Methods Stir Casting Slurry Casting Compocasting Liquid Metal Infiltration Squeeze Casting Pressure Infiltration Casting Pressureless Infiltration Spray Deposition Powder Metallurgy Methods Secondary Processing of Discontinuous MMCs Continuous-Fiber Aluminum MMCs Continuous-Fiber Reinforced Titanium Matrix Composites Continuous-Fiber TMC Processing Methods TMC Consolidation Procedures Secondary Fabrication of TMCs Particle-Reinforced TMCs Fiber Metal Laminates 567 Chapter 21 Ceramic Matrix Composites Reinforcements Matrix Materials Interfacial Coatings Fiber Architectures 580

7 x / Contents 21.5 Fabrication Methods Powder Processing Slurry Infiltration and Consolidation Polymer Infiltration and Pyrolysis (PIP) Space Shuttle C-C Process Conventional PIP Processes Sol-Gel Infiltration Chemical Vapor Infiltration (CVI) Directed Metal Oxidation (DMO) Liquid Silicon Infiltration (LSI) 594 Appendix A Metric Conversion Factors 597 Index 599