1944 Hakim S Sultan Alibori Advantage of Filament (1) Accurate, repeatable fibre placement from layer to layer and from part to part (2) Capability to use continuous fibres over the length of a component area (3) Glass Fibre can reduce weight by 25-35% and Carbon Fibre reduce weight by 40-60% if replaced with the steel as shown in Table 1 (5) Low tooling costs and Large structures can be produce ons (4)Weight Reduction= Fuel Economy Emission Reductio (6) High fibre volume content (7) Low material costs (8)Complex shape st be wound as a pre-form and then moulded to near net shape (9) High energy absorption (10) Strength& stiffness: high value, directional property (11) Surface properties: corrosion resistant, weather, resistant, tailored surface (12)Low thermal conductivity, low coefficient of thermal expansion. Torsion stiffness axial stiffness tensile strength. hardness abrasion and wear resistance 8 Table 1: Lightweight Material and material replaced with the mass Reduction Material Mass Reduction Relative Cost ightweight material Replaced (per part) High Strength Steel Mild Steel Aluminum(al) teel, Cast Iron 40-60 Magnesium Steel or Cast Iron/60-75 5-2.5 Magnesium Aluminum -1.5 Glass FRP Composites teel 5-35 -1.5 raphite FRP Composites Steel coCo 0-60 b-10+ Al matrix Composites Steel or Cast Iron 50-65 1.5-3+ Itanium Alloy steel 0-55 5-10+ Stainless Steel Carbon steel .2-1.7 ncludes both materials and manufacturing
1944 Hakim S. Sultan Aljibori Advantage of Filament (1) Accurate, repeatable fibre placement from layer to layer and from part to part. (2) Capability to use continuous fibres over the length of a component area (3) Glass Fibre can reduce weight by 25 -35% and Carbon Fibre reduce weight by 40-60% if replaced with the steel as shown in Table 1. (4) Weight Reduction = Fuel Economy & Emission Reductions (5) Low tooling costs and Large structures can be produced (6) High fibre volume content (7) Low material costs (8) Complex shapes can first be wound as a pre-form and then moulded to near net shape (9) High energy absorption (10) Strength & stiffness: high value, directional property (11) Surface properties: corrosion resistant, weather, resistant, tailored surface finish. (12) Low thermal conductivity, low coefficient of thermal expansion.Torsion stiffness, axial stiffness, tensile strength, hardness, abrasion and wear resistance [8]. Table 1: Lightweight Material and material replaced with the mass Reduction. Lightweight Material Material Replaced Mass Reduction (%) Relative Cost (per part)* High Strength Steel Mild Steel 10 1 Aluminum (AI) Steel, Cast Iron 40 - 60 1.3 - 2 Magnesium Steel or Cast Iron 60 - 75 1.5 - 2.5 Magnesium Aluminum 25 - 35 1 - 1.5 Glass FRP Composites Steel 25 - 35 1 - 1.5 Graphite FRP Composites Steel 50 - 60 2 - 10+ Al matrix Composites Steel or Cast Iron 50 - 65 1.5 - 3+ Titanium Alloy Steel 40 - 55 1.5 - 10+ Stainless Steel Carbon Steel 20 - 45 1.2 - 1.7 * Includes both materials and manufacturing
Fibre Reinforced Composite(FRC) Structures 1945 Table 2: Typical Properties of Filament Wound Pipes( Glass Fiber Reinforced) Property Typical Predominant Process Variables Values Density 188-2.26 Glass/Resin ratio Tensile Strength. MPa 344-1034Glass Type, Glass/Resin Ratio Compressive Strength MPa 276-551 Glass/Resin Ratio, Resin Type Shear Strength, MPa, Interlaminar21-137 Resin Type, Glass/Resin Ratio, Resin t Modulus of Elasticity(Tension),21-41 Glass type, Wind Pattern GPa Modulus of Rigidity, (Torsion), 11-14 Wind Pattern Flexural strengt 344-517 Wind Pattern Glass/ Resin Ratio *The Predominant Process Variables are those, which have the greatest influence upon the range in the particular values reported Disadvantage of filament Some limitations of filament winding, these limitations are discussed below: a) Shape of component must be such that the mandrel can be removed Therefore, segmented mandrels or a mandrel made from sacrificial material such as plaster, may be used for parts with complex geometry. The mandrel is disassembled or dissolved after the part is cured and also difficulty in winding reverse curvatures(concave) b)relatively rough exterior surface (c) Expensive raw materials and higher fabrication cost and susceptibility to moisture It should be pointed out that structural materials are generally far more efficient in an extensional rather than in a flexural mode, making the arch and shell preferable over the beam and plate [8]. In general the layers are wound on a rotating mandrel,as presented in Figures 5 and 6
Fibre Reinforced Composite (FRC) Structures 1945 Table 2: Typical Properties of Filament Wound Pipes (Glass Fiber Reinforced). Disadvantage of Filament Some limitations of filament winding, these limitations are discussed below: (a) Shape of component must be such that the mandrel can be removed. Therefore, segmented mandrels or a mandrel made from sacrificial material, such as plaster, may be used for parts with complex geometry. The mandrel is disassembled or dissolved after the part is cured and also difficulty in winding reverse curvatures (concave). (b) Relatively rough exterior surface. (c) Expensive raw materials and higher fabrication cost and susceptibility to moisture. It should be pointed out that structural materials are generally far more efficient in an extensional rather than in a flexural mode, making the arch and shell preferable over the beam and plate [8]. In general the layers are wound on a rotating mandrel, as presented in Figures 5 and 6. Property Typical Values Predominant Process Variables* Density 1.88-2.26 Glass/Resin Ratio Tensile Strength, MPa 344-1034 Glass Type, Glass/Resin Ratio Compressive Strength, MPa 276-551 Glass/Resin Ratio, Resin Type, Shear Strength, MPa, Interlaminar 21-137 Resin Type, Glass/Resin Ratio, Resin Type Modulus of Elasticity (Tension), GPa 21-41 Glass type, Wind Pattern Modulus of Rigidity,(Torsion), GPa 11-14 Wind Pattern Flexural Strength 344-517 Wind Pattern, Glass/Resin Ratio *The Predominant Process Variables are those, which have the greatest influence upon the range in the particular values reported