20 /Structural Composite Materials Low-Velocity Impact Event Delaminated Plies and Matrix Cracking Ultrasonic C-Scan Fig.1.24 Delaminations and matrix cracking in polymer matrix composite due to impact damage The major automakers (Fig.1.28)are in- For high-performance Formula I racing cars, creasingly turning to composites to help them where cost is not an impediment,most of the meet performance and weight requirements, chassis,including the monocoque,suspension, thus improving fuel efficiency.Cost is a major wings,and engine cover,is made from carbon driver for commercial transportation,and com- fiber composites. posites offer lower weight and lower mainte- Corrosion is a major headache and expense for nance costs.Typical materials are fiberglass/ the marine industry.Composites help minimize polyurethane made by liquid or compression these problems,primarily because they do not molding and fiberglass/polyester made by corrode like metals or rot like wood.Hulls of compression molding.Recreational vehicles boats ranging from small fishing boats to large have long used glass fibers,mostly for their du- racing yachts (Fig.1.29)are routinely made of rability and weight savings over metal.The glass fibers and polyester or vinyl ester resins product form is typically fiberglass sheet mold- Masts are frequently fabricated from carbon fiber ing compound made by compression molding. composites.Fiberglass filament-wound SCUBA
20 / Structural Composite Materials The major automakers (Fig. 1.28) are increasingly turning to composites to help them meet performance and weight requirements, thus improving fuel efficiency. Cost is a major driver for commercial transportation, and composites offer lower weight and lower maintenance costs. Typical materials are fiberglass/ polyurethane made by liquid or compression molding and fiberglass/ polyester made by compression molding. Recreational vehicles have long used glass fibers, mostly for their durability and weight savings over metal. The product form is typically fiberglass sheet molding compound made by compression molding. For high-performance Formula 1 racing cars, where cost is not an impediment, most of the chassis, including the monocoque, suspension, wings, and engine cover, is made from carbon fiber composites. Corrosion is a major headache and expense for the marine industry. Composites help minimize these problems, primarily because they do not corrode like metals or rot like wood. Hulls of boats ranging from small fishing boats to large racing yachts (Fig. 1.29) are routinely made of glass fibers and polyester or vinyl ester resins. Masts are frequently fabricated from carbon fiber composites. Fiberglass filament-wound SCUBA Fig. 1.24 Delaminations and matrix cracking in polymer matrix composite due to impact damage
Chapter 1:Introduction to Composite Materials /21 F-15 Eagle AV-8B Harrier Early 1970s Early 1980s 2%Composites 27%Composites F/A-18 Hornet Mid-1970s 10%Composites F/A-18 E/F Hornet Late 1990s 21%Composites Fig.1.25 Typical fighter aircraft applications.Source:The Boeing Company tanks are another example of composites im- In the United States alone,it is estimated that proving the marine industry.Lighter tanks can more than 250,000 structures,such as bridges hold more air yet require less maintenance than and parking garages,need repair,retrofit,or re- their metallic counterparts.Jet skis and boat trail- placement.Composites offer much longer life ers often contain glass composites to help mini- with less maintenance due to their corrosion re- mize weight and reduce corrosion.More re- sistance.Typical processes/materials include wet cently,the topside structures of many naval ships lay-up repairs and corrosion-resistant fiberglass have been fabricated from composites. pultruded products. Using composites to improve the infrastruc- In construction (Fig.1.31),pultruded fiber- ture(Fig.1.30)of our roads and bridges is a rela- glass rebar is used to strengthen concrete,and tively new,exciting application.Many of the glass fibers are used in some shingling materials. world's roads and bridges are badly corroded and With the number of mature tall trees dwindling, in need of continual maintenance or replacement. the use of composites for electrical towers and
Chapter 1: Introduction to Composite Materials / 21 tanks are another example of composites improving the marine industry. Lighter tanks can hold more air yet require less maintenance than their metallic counterparts. Jet skis and boat trailers often contain glass composites to help minimize weight and reduce corrosion. More recently, the topside structures of many naval ships have been fabricated from composites. Using composites to improve the infrastructure (Fig. 1.30) of our roads and bridges is a relatively new, exciting application. Many of the world’s roads and bridges are badly corroded and in need of continual maintenance or replacement. In the United States alone, it is estimated that more than 250,000 structures, such as bridges and parking garages, need repair, retrofit, or replacement. Composites offer much longer life with less maintenance due to their corrosion resistance. Typical processes/materials include wet lay-up repairs and corrosion-resistant fiberglass pultruded products. In construction (Fig. 1.31), pultruded fiberglass rebar is used to strengthen concrete, and glass fibers are used in some shingling materials. With the number of mature tall trees dwindling, the use of composites for electrical towers and Fig. 1.25 Typical fighter aircraft applications. Source: The Boeing Company
22 Structural Composite Materials Carbon Laminate Carbon Sandwich Fiberglass Aluminum 50%Composite Structure Aluminum/Steel/Titanium Pylons Fig.1.26 Boeing787 Dreamliner commercial airplane.Source:The Boeing Company 1N Fig.1.27 Launch and spacecraft structures
22 / Structural Composite Materials Fig. 1.26 Boeing 787 Dreamliner commercial airplane. Source: The Boeing Company Fig. 1.27 Launch and spacecraft structures
Chapter 1:Introduction to Composite Materials /23 Composites are used in both trucks and cars to reduce weight and Increase fuel efficiency. Recreational vehicles have long used fiberglass composites, mostly for its durability and weight savings over metal. Fig.1.28 Transportation applications light poles is greatly increasing.Typically,these improve electrical energy generation efficiency. are pultruded or filament-wound glass. These blades can be as long as 120 ft(37 m)and Wind power is the world's fastest-growing en- weigh up to 11,500 lb(5200 kg).In 2007,nearly ergy source.The blades for large wind turbines 50,000 blades for 17,000 turbines were deliv- (Fig.1.32)are normally made of composites to ered,representing roughly 400 million pounds
Chapter 1: Introduction to Composite Materials / 23 light poles is greatly increasing. Typically, these are pultruded or filament-wound glass. Wind power is the world’s fastest-growing energy source. The blades for large wind turbines (Fig. 1.32) are normally made of composites to improve electrical energy generation efficiency. These blades can be as long as 120 ft (37 m) and weigh up to 11,500 lb (5200 kg). In 2007, nearly 50,000 blades for 17,000 turbines were delivered, representing roughly 400 million pounds Fig. 1.28 Transportation applications
24 Structural Composite Materials Rigid and flexible oil gas tubulars Maintenance and corrosion in either fresh or salt water can be major headaches and expenses. Composites help minimize those problems. Racing sailboat hulls and equipment More recently,composites are being used for major components In naval ships. Fig.1.29 Marine applications (approximately 180 million kg)of composites. Tennis racquets(Fig.1.33)have been made of The predominant material is continuous glass glass for years,and many golf club shafts are fibers manufactured by either lay-up or resin made of carbon.Processes include compression infusion. molding for tennis racquets and tape wrapping or
24 / Structural Composite Materials (approximately 180 million kg) of composites. The predominant material is continuous glass fibers manufactured by either lay-up or resin infusion. Tennis racquets (Fig. 1.33) have been made of glass for years, and many golf club shafts are made of carbon. Processes include compression molding for tennis racquets and tape wrapping or Fig. 1.29 Marine applications