Free Download Engineering | Science | Technology Books

Composite Materials Handbook – Vol 3

File : pdf, 8.4 MB, 693 pages

TOC

CHAPT 1 GENERAL INFORMATION
1.1 INTRODUCTION
1.2 PURPOSE, SCOPE, AND ORGANIZATION OF VOLUME 3
1.3 SYMBOLS, ABBREVIATIONS, AND SYSTEMS OF UNITS
1.3.1 Symbols and abbreviations
1.3.1.1 Constituent properties
1.3.1.2 Laminae and laminates
1.3.1.3 Subscripts
1.3.1.4 Superscripts
1.3.1.5 Acronyms
1.3.2 System of units
1.4 DEFINITIONS

CHAPT 2 MATERIALS AND PROCESSES – THE EFFECTS OF VARIABILITY ON COMPOSITE PROPERTIES 1
2.1 INTRODUCTION
2.2 PURPOSE
2.3 SCOPE
2.4 CONSTITUENT MATERIALS
2.4.1 Fibers
2.4.1.1 Carbon and graphite fibers
2.4.1.1.1 Carbon vs. graphite
2.4.1.1.2 General material description
2.4.1.1.3 Processing
2.4.1.1.4 Typical properties
2.4.1.7 Quartz
2.4.1.8 Ultrahigh molecular weight polyethylene.
2.4.2 Resins
2.4.2.1 Overview
2.4.2.2 Epoxy
2.4.2.3 Polyester (thermosetting)
2.4.2.4 Phenolic
2.4.2.5 Bismaleimide
2.4.2.6 Polyimides
2.4.2.7 Thermoplastic materials
2.4.2.8 Specialty and emerging resin systems
2.5 PROCESSING OF PRODUCT FORMS
2.5.1 Fabrics and preforms
2.5.1.1 Woven fabrics
2.5.2 Preimpregnated forms
2.6 SHIPPING AND STORAGE PROCESSES
2.7 CONSTRUCTION PROCESSES
2.7.1 Hand lay-up
2.7.2 Automated tape placement/automated tape lamination
2.7.3 Automated tow placement/fiber placement
2.7.4 Braiding
2.7.5 Filament winding
2.7.6 Pultrusion
2.7.7 Sandwich construction
2.7.8 Adhesive bonding
2.7.9 Prebond moisture
2.8 CURE AND CONSOLIDATION PROCESSES
2.8.1 Vacuum bag molding
2.8.2 Oven cure
2.8.3 Autoclave curing processing
2.8.4 Press molding
2.8.5 Integrally heated tooling
2.8.6 Pultrusion die cure and consolidation
2.8.7 Resin transfer molding (RTM)
2.8.8 Thermoforming
2.9 ASSEMBLY PROCESSES
2.10 PROCESS CONTROL
2.10.1 Common process control schemes
2.10.2 Example – autoclave cure of a thermoset composite
2.11 PREPARING MATERIAL AND PROCESSING SPECIFICATIONS
2.11.1 Types of specifications
2.11.2 Format for specifications
2.11.3 Specification examples
2.11.4 Configuration management

CHAPT 3 QUALITY CONTROL OF PRODUCTION MATERIALS AND PROCESSES
3.1 INTRODUCTION
3.2 MATERIAL PROCUREMENT QUALITY ASSURANCE PROCEDURES
3.2.1 Specifications and documentation
3.2.2 Receiving inspection
3.3 PART FABRICATION VERIFICATION
3.3.1 Process verification
3.3.2 Nondestructive inspection
3.3.3 Destructive tests
3.4 STATISTICAL PROCESS CONTROL
3.4.1 Introduction
3.4.2 Quality tools
3.4.3 Gathering and plotting data
3.4.4 Control charts
3.4.5 Process capability
3.4.6 Troubleshooting and improvement
3.4.7 Lot acceptance
3.5 MANAGING CHANGE IN MATERIALS AND PROCESSES
3.5.1 Introduction
3.5.2 Qualification of new materials or processes
3.5.2.1 Problem statement
3.5.2.2 Business case
3.5.2.3 Divergence and risk
3.5.2.4 Technical acceptability
3.5.2.5 Allowables development and equivalency validation
3.5.2.6 Production readiness
3.5.2.7 Lessons learned
3.5.3 Divergence and risk
3.5.4 Production readiness

CHAPT 4 BUILDING BLOCK APPROACH FOR COMPOSITE STRUCTURES
4.1 INTRODUCTION AND PHILOSOPHY
4.2 RATIONALE AND ASSUMPTIONS
4.3 METHODOLOGY
4.3.1 General approach
4.4 CONSIDERATIONS FOR SPECIFIC APPLICATIONS
4.4.1 Aircraft for prototypes
4.4.1.1 PMC composite allowables generation for DOD/NASA prototype aircraft structure
4.4.1.2 PMC composites building block structural development for DOD/NASA prototype aircraft
4.4.1.3 Summary of allowables and building block test efforts for DOD/NASA prototype composite aircraft structure
4.4.2 Aircraft for EMD and production
4.4.2.1 PMC composite allowables generation for DOD/NASA EMD and production aircraft structure
4.4.2.2 PMC composite building block structural development for DOD/NASA EMD and production aircraft
4.4.2.3 Summary of allowables and building block test efforts for DOD/NASA EMD and production composite aircraft structure
4.4.3 Commercial aircraft
4.4.3.1 Introduction
4.4.3.2 The building block approach
4.4.3.3 Composite road map
4.4.3.4 Commercial building block approach
4.4.3.5 Group A, material property development
4.4.3.6 Group B, design-value development
4.4.3.7 Group C, analysis verification
4.4.3.8 Boeing 777 aircraft composite primary structure building block approach
4.4.4 Business and private aircraft
4.4.5 Rotorcraft
4.4.5.1 Design allowables testing
4.4.5.2 Design development testing
4.4.5.3 Full scale substantiation testing
4.4.6 Spacecraft
4.5 SPECIAL CONSIDERATION AND VARIANCES FOR SPECIFIC PROCESSES AND
MATERIAL FORMS
4.5.1 Room Temperature

CHAPT 5 DESIGN AND ANALYSIS
5.1 INTRODUCTION
5.2 BASIC LAMINA PROPERTIES AND MICROMECHANICS
5.2.1 Assumptions
5.2.2 Fiber composites: physical properties
5.2.2.1 Elastic properties
5.2.2.2 Viscoelastic properties
5.2.2.3 Thermal expansion and moisture swelling
5.2.2.4 Thermal conduction and moisture diffusion
5.2.3 Fiber composites: strength and failure
5.2.3.1 Axial tensile strength
5.2.3.2 Axial compressive strength
5.2.3.3 Matrix mode strength
5.2.4 Strength under combined stress
5.2.5 Summary
5.3 ANALYSIS OF LAMINATES
5.3.1 Lamina stress-strain relations
5.3.2 Lamination theory
5.3.3 Laminate properties
5.3.3.1 Membrane stresses
5.3.3.2 Bending
5.3.3.3 Thermal expansion
5.3.3.4 Moisture expansion
5.3.3.5 Conductivity
5.3.4 Thermal and hygroscopic analysis
5.3.4.1 Symmetric laminates
5.3.4.2 Unsymmetric laminates
5.3.5 Laminate stress analysis
5.3.5.1 Stresses due to mechanical loads
5.3.5.2 Stresses due to temperature and moisture
5.3.5.3 Netting analysis
5.3.5.3.1 Netting analysis for design of filament wound pressure vessels
5.3.5.4 Interlaminar stresses
5.3.5.5 Nonlinear stress analysis
5.4 LAMINATE STRENGTH AND FAILURE
5.4.1 Sequential ply failure approach
5.4.2 Fiber failure approach (laminate level failure)
5.4.3 Laminate design
5.4.4 Stress concentrations
5.4.5 Delamination
5.4.5.1 Compression
5.4.6 Damage and failure modes
5.4.6.1 Tension
5.4.6.2 Compression
5.5 COMPLEX LOADS
5.5.1 Biaxial in-plane loads
5.5.2 Out-of-plane loads
5.6 LAMINA TO LAMINATE CONSIDERATIONS
5.6.1 Residual stresses and strains
5.6.2 Thickness effects
5.6.3 Edge effects
5.6.4 Effects of transverse tensile properties in unidirectional tape
5.6.5 Laminate stacking sequence effects
5.6.6 Lamina-to-laminate statistics
5.7 COMPRESSIVE BUCKLING AND CRIPPLING
5.7.1 Plate buckling and crippling
5.7.1.6 Uniaxial and biaxial loading – plate with all sides simply supported
5.7.1.7 Uniaxial loading – plate with loaded edges simply supported and unloaded edges fixed
5.7.1.8 Stacking sequence effects in buckling
5.7.2 Compressive postbuckling and crippling
5.7.2.1 Analytical models
5.7.2.2 Fatigue effects
5.7.2.3 Crippling curve determination
5.7.2.4 Stiffener crippling strength determination
5.7.2.5 Effects of corner radii and fillets
5.7.2.6 Slenderness correction
5.8 CARPET PLOTS
5.9 CREEP AND RELAXATION
5.10 FATIGUE
5.11 VIBRATION
5.11.1 Introduction
5.11.2 Stacking sequence effects
5.12 OTHER STRUCTURAL PROPERTIES
5.13 COMPUTER PROGRAMS
5.14 CERTIFICATION REQUIREMENTS

CHAPT 6 STRUCTURAL BEHAVIOR OF JOINTS
6.1 INTRODUCTION
6.2 ADHESIVE JOINTS
6.2.1 Introduction
6.2.2 Joint design considerations
6.2.2.1 Effects of adherend thickness: adherend failures vs. bond failures
6.2.2.2 Joint geometry effects
6.2.2.3 Effects of adherend stiffness unbalance
6.2.2.4 Effects of ductile adhesive response
6.2.2.5 Behavior of composite adherends
6.2.2.6 Effects of bond defects
6.2.2.7 Durability of adhesive joints
6.2.3 Stresses and structural behavior of adhesive joints
6.2.3.1 General
6.2.3.2 Adhesive shear stresses
6.2.3.3 Peel stresses
6.2.3.4 Single and double lap joints with uniform adherend thickness
6.2.3.5 Tapered and multi-step adherends
6.2.3.6 Finite element modeling
6.2.4 Mechanical response of adhesives
6.2.5 Mechanical response of composite adherends
6.2.6 Adhesive joint conclusions
6.3 MECHANICALLY FASTENED JOINTS
6.3.1 Introduction
6.3.2 Structural analysis
6.3.2.1 Load sharing in a joint
6.3.2.2 Analysis of local failure in bolted joints
6.3.2.3 Failure criteria
6.3.3 Design considerations
6.3.3.1 Geometry
6.3.3.2 Lay-up and stacking sequence
6.3.3.3 Fastener selection
6.3.4 Fatigue
6.3.5 Test verification

CHAPT 7 DAMAGE RESISTANCE, DURABILITY, AND DAMAGE TOLERANCE
7.1 OVERVIEW AND GENERAL GUIDELINES
7.1.1 Principles
7.1.2 Composite-related issues
7.1.3 General guidelines
7.1.4 Section organization
7.2 AIRCRAFT DAMAGE TOLERANCE
7.2.1 Evolving military and civil aviation requirements
7.2.2 Methods of compliance to aviation regulations
7.2.2.1 Compliance with static strength requirements (civil aviation)
7.2.2.2 Compliance with damage tolerance requirements (civil aviation)
7.2.2.3 Deterministic compliance method (civil aviation example)
7.2.2.4 Probabilistic or semi-probabilistic compliance methods (civil aviation)
7.2.2.5 Comparison of deterministic and probabilistic methods
7.2.2.6 Full-scale tests for proof of structure (civil aviation)
7.3 TYPES, CHARACTERISTICS, AND SOURCES OF DAMAGE
7.3.1 Damages characterized by stage of occurrence
7.3.1.1 Manufacturing
7.3.1.2 Service
7.3.2 Damages characterized by physical imperfection
7.3.3 Realistic impact energy threats to aircraft
7.4 INSPECTION FOR DAMAGE
7.4.1 Aircraft inspection programs
7.4.2 Recommendations for damage inspection data development
7.5 DAMAGE RESISTANCE
7.5.1 Influencing factors
7.5.1.1 Summary of results from previous impact studies
7.5.1.2 Through-penetration impacts
7.5.1.3 Material type and form effects
7.5.1.4 Depth of damage
7.5.1.5 Laminate thickness effects
7.5.1.6 Structural size effects
7.5.1.7 Sandwich structure
7.5.2 Design issues and guidelines
7.5.3 Test issues
7.5.4 Analysis methods – description and assessment
7.6 DURABILITY (DAMAGE INITIATION)
7.6.1 Introduction
7.6.2 Life factor approach
7.6.3 Load enhancement factor approach
7.6.4 Ultimate strength approach
7.6.5 Spectrum truncation
7.6.6 Durability certification
7.6.7 Influencing factors
7.6.8 Design issues and guidelines
7.6.9 Test issues
7.6.10 Analysis methods – description and assessment
7.7 DAMAGE GROWTH UNDER CYCLIC LOADING
7.7.1 Influencing factors
7.7.2 Design issues and guidelines
7.7.3 Test issues
7.7.4 Analysis methods – description and assessment
7.8 RESIDUAL STRENGTH
7.8.1 Influencing Factors
7.8.1.1 Relationships between damage resistance and residual strength
7.8.1.2 Structure with impact damage
7.8.1.2.1 Material effects
7.8.1.2.2 Interlaminar toughness effects
7.8.1.2.3 Stacking sequence effects
7.8.1.2.4 Laminate thickness effects
7.8.1.2.5 Through-thickness stitching
7.8.1.2.6 Sandwich structure
7.8.1.2.7 Impact characteristic damage states
7.8.1.2.8 Residual strength – compressive/shear loads
7.8.1.2.9 Residual strength – tensile loads
7.8.1.2.10 Stiffened panels
7.8.1.3 Structure with through-penetration damage
7.8.1.3.1 Stitched skin/stiffener panels
7.8.2 Design issues and guidelines
7.8.2.1 Stacking sequences
7.8.2.2 Sandwich structure
7.8.3 Test issues
7.8.4 Analysis methods – description and assessment
7.8.4.1 Large through-penetration damage
7.8.4.1.1 Reduced singularity (Mar-Lin) model
7.8.4.1.2 Strain softening laws
7.8.4.1.3 LEFM – based methods
7.8.4.1.4 R-curves
7.8.4.2 Single delaminations and disbonds
7.8.4.2.1 Fracture mechanics approaches
7.8.4.2.2 Sublaminate buckling methods
7.8.4.3 Impact damages
7.8.4.3.1 Sublaminate buckling methods
7.8.4.3.2 Strain softening methods
7.8.4.4 Cuts and gouges
7.9 APPLICATIONS/EXAMPLES

CHAPT 8 SUPPORTABILITY
8.1 INTRODUCTION
8.2 DESIGN FOR SUPPORTABILITY
8.2.1 In-service experience
8.2.2 Inspectability
8.2.3 Material selection
8.2.4 Damage resistance, damage tolerance, and durability
8.2.5 Environmental compliance
8.2.5.1 Elimination/reduction of heavy metals
8.2.5.2 Consideration of paint removal requirements
8.2.5.3 Shelf life and storage stability of repair materials
8.2.5.4 Cleaning requirements
8.2.5.5 Non-destructive inspection requirements
8.2.5.6 End of life disposal considerations
8.2.6 Reliability and maintainability
8.2.7 Interchangeability and replaceability
8.2.8 Accessibility
8.2.9 Repairability
8.2.9.1 General design approach
8.2.9.2 Repair design issues
8.3 SUPPORT IMPLEMENTATION
8.3.1 Part Inspection
8.3.2 Damage assessment for composite repairs
8.3.3 Repair design criteria
8.3.4 Repair of composite structures
8.4 COMPOSITE REPAIR OF METAL STRUCTURE (CRMS)
8.5 LOGISTICS REQUIREMENTS

CHAPT 9 STRUCTURAL RELIABILITY
9.1 INTRODUCTION
9.2 FACTORS AFFECTING STRUCTURAL RELIABILITY
9.2.1 Static strength
9.2.2 Environmental effects
9.2.3 Fatigue
9.2.4 Damage tolerance
9.3 RELIABILITY ENGINEERING
9.4 RELIABILITY DESIGN CONSIDERATIONS
9.5 RELIABILITY ASSESSMENT AND DESIGN
9.5.1 Background
9.5.2 Deterministic vs. Probabilistic Design Approach
9.5.3 Probabilistic Design Methodology
9.5.4 Data Requirements
9.5.5 Summary
9.6 RELIABILITY BASED STRUCTURAL QUALIFICATION
9.7 LIFE CYCLE REALIZATION

CHAPT 10 THICK-SECTION COMPOSITES
10.1 INTRODUCTION AND DEFINITION OF THICK-SECTION
10.2 MECHANICAL PROPERTIES REQUIRED FOR THICK-SECTION COMPOSITE THREEDIMENSIONAL ANALYSIS
10.2.1 2-D composite analysis
10.2.2 3-D composite analysis
10.2.2.1 Unidirectional lamina 3-D properties
10.2.2.2 Oriented orthotropic laminate 3-D properties
10.2.3 Experimental property determination
10.2.3.1 Uniaxial tests
10.2.3.2 Multiaxial tests
10.2.3.2.1 Lineal test specimens/techniques
10.2.3.2.2 Cylindrical test specimens/techniques
10.2.4 Theoretical property determination
10.2.4.1 3-D lamina property determination
10.2.4.2 3-D laminate property determination
10.2.5 Test specimen design considerations
10.3 STRUCTURAL ANALYSIS METHODS FOR THICK-SECTION COMPOSITES
10.4 PHYSICAL PROPERTY ANALYSIS REQUIRED FOR THICK-SECTION COMPOSITE THREE-DIMENSIONAL ANALYSIS
10.5 PROCESS ANALYSIS METHODS FOR THICK-SECTION COMPOSITES
10.6 FAILURE CRITERIA
10.7 FACTORS INFLUENCING THICK-SECTION ALLOWABLES (I.E., SAFETY MARGINS)
10.8 THICK LAMINATE DEMONSTRATION PROBLEM

CHAPT 11 ENVIRONMENTAL MANAGEMENT
11.1 INTRODUCTION
11.2 RECYCLING INFRASTRUCTURE
11.3 ECONOMICS OF COMPOSITE RECYCLING
11.4 COMPOSITE WASTE STREAMS
11.4.1 Process waste
11.4.2 Post consumer composite waste
11.5 COMPOSITE WASTE STREAM SOURCE REDUCTION
11.5.1 Just-in-time and just enough material delivery
11.5.2 Electronic commerce acquisition management
11.5.3 Waste minimization guidelines
11.5.4 Lightweighting
11.6 REUSE OF COMPOSITE COMPONENTS AND MATERIALS
11.6.1 Reuse of composite components
11.6.2 Machining to smaller components
11.7 MATERIALS EXCHANGE
11.7.1 Reallocation of precursors
11.7.2 Composite materials exchange services
11.8 RECYCLING OF COMPOSITE MATERIALS
11.8.1 Design for disassembly and recycling
11.8.2 Recycling logistics
11.8.3 Processing of composite recyclate
11.8.4 Recycling of waste prepreg

CHAPT 12 LESSONS LEARNED
12.1 INTRODUCTION
12.2 UNIQUE ISSUES FOR COMPOSITES
12.2.1 Elastic properties
12.2.2 Tailored properties and out-of-plane loads
12.2.3 Damage tolerance
12.2.4 Durability
12.2.5 Environmental sensitivity
12.2.6 Joints
12.2.6.1 Mechanically-fastened joints
12.2.6.2 Problems associated with adhesive bonding to peel-ply composite surfaces
12.2.7 Design
12.2.8 Handling and storage
12.2.9 Processing and fabrication
12.2.9.1 Quality control
12.3 LESSONS LEARNED
12.3.1 Design and analysis
12.3.1.1 Sandwich design
12.3.1.2 Bolted joints
12.3.1.3 Bonded joints
12.3.1.4 Composite to metal splice joints
12.3.1.5 Composite to metal continuous joints
12.3.1.6 Composite to composite splice joints
12.3.2 Materials and processes
12.3.3 Fabrication and assembly
12.3.4 Quality control
12.3.5 Testing
12.3.6 Certification
12.3.7 In-service and repair

Download               :                 link