filament winding composite structure fabrication - Perdana Library

FILAMENT WINDING COMPOSITE STRUCTURE FABRICATION

S.T. Peters W.D. Humphrey R.F Foral

Table of Contents

PREFACE

iii

DEDICATION

iv

ACKNOWLEDGEMENTS

v

FILAMENT WINDING OVERVIEW

1-1

1.1 Introduction 1.2 Design Considerations 1.3 Fabrication Considerations

1-1 1-2 1-2

FIBERS AND RESIN SYSTEMS

2-1

2.1 Introduction 2.2 Fibers 2.3 Resin Systems 2.3.1 Wet Resin Systems 2.3.2 Preformulated Resin Systems 2.3.3 Pregpreg Resin Systems 2.4 Toughened Resin Systems

2-1 2-1 2-4 2-6 2-9 2-9 2-9

MANUFACTURING PROCESS

3-1

3.1 Introduction 3.2 Material Selection 3.3 Shape Considerations 3.3.1 Round Cylindrical.

3-1 3-1 3-1 3-2

3.4 Size

3-3

3.5 Configuration 3.5.1 Cylindrical With Domes 3.5.2 Spherical 3.5.3 Cylinders and Shafts 3.5.4 Flat Cylinders (Flywheels) 3.6 Winding Patterns 3.6.1 Helical Winding 3.6.2 Polar Winding 3.6.3 Hoop Patterns 3.7 Winding Machine Accuracy 3.8 Winding Operation 3.8.1 Impregnation 3.8.2 Prepreg (Commercial) 3.8.3 Wet Winding

3-3 3-4 3-4 3-4 3-4 3-4 3-6 3-6 3-6 3-6 3-7 3-10 3-10 3-10

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3.8.4 3.8.5 3.8.6 3.8.7 3.8.8

Mandrel Preparation Component Winding Skirt Fabrication (For Rocket Motors) B-stage/Cure Mandrel Removal

TOOLING AND EQUIPMENT

3-10 3-11 3-12 3-12 3-13 4-1

4.1 Introduction 4.2 Mandrel Design 4.2.1 Materials 4.2.2 Mandrel Types 4.3 Winding Machines 4.3.1 Helical Winders 4.3.2 Polar Winders 4.3.3 Tumble Winder 4.4 Delivery Systems 4.5 Tensioners 4.6 Ovens

4-1 4-1 4-1 4-1 4-4 4-5 4-8 4-8 4-8 4-9 4-10

ANALYSIS AND DESIGN OF FILAMENT WOUND LAMINATES 5.1 Introduction 5.2 Terminology 5.2.1 Stress and Strain 5.2.2 Mechanical Properties 5.3 Ply Mechanical Behavior 5.3.1 Properties Relative to the Ply Axes. 5.3.2 Ply Properties Relative to Laminate Axes 5.4 Laminate Mechanical Behavior 5.4.1 Classical Lamination Theory 5.4.2 Temperature/Moisture Effects 5.4.3 Laminate Strength Predictions 5.4.4 Computer Analysis 5.4.1 Simple Laminate Behavior 5.5 Design Applications 5.5.1 Laminate Description Code 5.5.3 Thin Walled Cylinders 5.5.4 Netting Analysis 5.5.5 Other Design Considerations MECHANICAL TESTING OF LAMINATED COMPOSITES 6.1 Introduction 6.2 Constituent Properties 6.2.1 Fiber Properties 6.2.2 Resin Properties. 6.3 Test Specimen Configuration 6.3.1 Flat Specimens (Figure 6-2-1).

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5-1 5-1 5-1 5-2 5-2 5-3 5-4 5-9 5-16 5-16 5-21 5-23 5-27 5-27 5-28 5-28 5-32 5-33 5-42 6-1 6-1 6-2 6-3 6-3 6-3 6-5

6.3.2 Ring Specimens (Figure 6-2-II). 6.3.3 Tubular Specimens (Figure 6-2-III). 6.3.4 Specimen Conditioning. 6.4 Unidirectional Ply Properties. 6.4.1 Longitudinal Tension - E1, v12 FL Properties. 6.4.2 Transverse Tension - E2, V21, fl Properties.

6-6 6-6 6-6 6-6 6-8 6-10

6.4.3 Longitudinal Compression - E\, vn, Ft Properties.

6-11

6.4.4 Transverse Compression - £2, "21, Ft Properties

6-12

6.4.4 In-plane Shear- G12 and Fi,T Properties 6.4.6 Hygrothermal Effects -a\, a2 P1, and /S2 Properties. 6.5 Laminate Properties in Combined Loading. 6.5.1 Standard Pressure Bottles. 6.5.2 Combined Load Testing of Tubular Specimens. 6.5.3 Stacking Sequence Effects. 6.5.4 Laminate Toughness.

COMPOSITE JOINTS

6-12 6-14 6-14 6-14 6-16 6-19 6-21

7-1

7.1 Introduction 7.2 Pressure Closures 7.2.1 Closed End Pressure Vessels 7.2.2 Metal-Lined Closed End Pressure Vessels 7.2.3 Pressure Closures with Full Diameter Openings 7.3 Structural Joints 7.3.1 Torsion End Couplings 7.3.2 Machined, Drilled, and Pinned 7.3.3 Bonded Interference 7.3.4 The No Cut Fiber Couplings (NCF) 7.3.5 Tapered Adhesive Joint 7.3.6 Flanged Face Joint 7.3.7 Tension-Compression Fittings 7.3.8 Trapped Taper 7.3.9 Trapped Taper With Compression Ring 7.3.10 Self Locking Joints 7.3.11 Screw Threads ENVIRONMENTAL EFFECTS

7-1 7-1 7-1 7-6 7-6 7-9 7-10 7-10 7-11 7-11 7-13 7-13 7-15 7-15 7-15 7-15 7-16 8-1

8.1 Introduction 8.2 Composite Aging Overview 8.2.1 Fiberglass/Epoxy Aircraft Structures 8.2.2 Kevlar®, Graphite/Epoxy Aircraft Structures 8.3 Composite Aging In Motor Cases 8.3.1 Thermal Spikes 8.3.2 Resin Effects 8.3.3 Reinforcement Effects

IX

8-1 8-1 8-1 8-4 8-5 8-7 8-7 8-7

8.3.4 Fiberglass 8.3.5 Kevlar® 8.3.6 Graphite 8.4 Summary

QUALITY ASSURANCE 9.1 Introduction 9.2 Incoming Materials Inspection 9.3 In-process Inspections 9.3.1 Trial Winding 9.3.2 Component Fabrication 9.3.3 In-Process Documentation 9.4 Final Inspection 9.4.1 Nondestructive Inspection Techniques 9.4.2 Documentation

APPLICATIONS 10.1 Introduction 10.2 Aerospace Applications 10.3 Marine Applications 10.4 Ordinance Items 10.5 Commercial Applications 10.6 New Developments

8-7 8-9 8-10 8-10

9-1 9-1 9-1 9-1 9-1 9-1 9-3 9-9 9-9 9-10

10-1 10-1 10-1 10-6 10-9 10-10 10-13

HISTORY AND PATENT OVERVIEW

11-1

11.1 Introduction 11.2 Development History 11.3 Patent History 11.3 Sources 11.4 Patents

11-1 11-1 11-1 11-3 11-3

Appendix I SUPPLIERS A. Fiber Suppliers B. Resin Suppliers C. Prepreg Suppliers D. Suppliers of Winding Machines E. Suppliers of Creels, Impregnators, and Other Accessories Appendix II FILAMENT-WOUND COMPOSITE FABRICATORS A. Commercial Filament Winders B. Advanced Fiber Commercial Vendors C. Aerospace-Oriented Filament Winders D. Composite Fabrications, Not Exclusively Filament Winding

1-1 1-1 1-2 1-3 1-3 1-4 II-l II-l II-5 II-6 II-7

Appendix III REFERENCE INDEX

I III

A. Periodicals B: Technical Societies C: Standards Making Organizations Related to Composites D: Composite and Filament Wmding Instruction E. Reference Books on Composites Appendix IV GLOSSARY OF FILAMENT WINDING TERMS

XI

III-l III-3 III-5 III-6 III-8 IV-1