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Overview of Advanced Composite Materials and StructuresMaterials and StructuresAbout these slides:
• The center on Advanced Materials In Transport Aircraft Structures (AMTAS):
- was established in 2003- is part of the FAA Center of Excellence program- involves 6 colleges/universities: UW (lead), WSU, EdCC, OSU, g ( ), , , ,UoU, and FIU
- involves several aerospace companies (primarily Boeing)- maintains a website with additional details:
http://depts.washington.edu/amtas/
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Overview of Advanced Composite M t i l d St tMaterials and StructuresAbout these slides:About these slides:
• A composite short course intended for practicing engineers d l d b AMTAS ti i twas developed by AMTAS participants
• These slides were extracted from the AMTAS short course
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AcknowledgementsJohn GokcenDick BossiE i C
Peter JanickiJohn WellerEric Cregger
Dave Dickson Chris EastlandDoug McCarville Dodd Grande
John Weller
Doug McCarville Moe Soleiman Patrick Stickler Eric Casterline
Bruno BoursierFrank Ko
Dayton Griffith Bud DasPaolo FeraboliBrian Flinn
Dave KehrlBrian FlinnKuen LinMark Tuttle
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
What is a ‘Composite Material’?
“A composite material is one in which two (or more) materials are bonded together to form a third material.” g
… is a material consisting of:93.5% Al, 4.4% Cu, 0.6% Mn,1.5% Mg
a composite?
(this material is known as the 2024 aluminum alloy)
N 2024 Al i t id d t b it- No, 2024 Al is not considered to be a composite- Definition is missing a reference to physical scale
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
What is a ‘Composite Material’?
“A composite material is a material system consisting of two (or more) materials that are distinct at a physical scale greater than ) p y gabout 1 x 10-6 m (1 m), and which are bonded together at the
atomic and/or molecular levels.”
To put this physical scale in context:
…the diameter of the human hair ranges from 30-60 m…objects with a dimension of 1 m can be easily seen with
an optical microscope
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
• Composites typically consist of:– Relatively strong and stiff reinforcing material, that is– Embedded within a relatively weaker and more compliant
matrix materialmatrix material
• Composites have been used for centuries (clay bricks p ( yreinforced with straw; papyrus reeds embedded in a natural pitch matrix; etc)
• Composites occur naturally:• Wood: cellulose fibers in a lignin matrix• Bone: collagen fibers in a (mostly) calcium phosphate matrix
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
• ‘Advanced’ (or ‘modern’) composites are engineered materials developed within past 80 yrsengineered materials developed within ~past 80 yrs
• First commercially successful advanced composite• First commercially successful advanced composite is commonly known as ‘fiberglass’: glass reinforcing fibers embedded within a polymer g p ymatrix (usually polyester, vinyl ester, or epoxy)
• Advanced composites often classified according to– Type of matrix material, or– Physical form of reinforcing material
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
• Classification by type of matrix material:
– Polymer Matrix Composites (PMCs)• e.g., polyester, epoxy, bismaleimide, phenolic matrices
– Metal Matrix Composites (MMCs) • e.g., aluminum, titanium or magnesium matrices
– Ceramic Matrix Composites (CMCs) • e.g., silicon carbide (SiC), silicon nitride (Si3N4), aluminum oxide
(Al2O3) matrices
• Approximate maximum service temperatures:• PMCs: up to about 350ºC (630ºF), depending on polymerp ( ), p g p y• MMCs: up to about 500ºC (900ºF), depending on metal • CMC: up to about 1200ºC (2100ºF), depending on ceramic
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
• Classification by physical form of reinforcing material:
– Particulate: roughly spherical reinforcing particles with diameters ~ 1-100 μmWhisker:– Whisker:
• diameters ~ 5-30 m• lengths < 10 mm
Chopped glass fiberlengths 10 mm
– Short (or "chopped") fiber:• diameters ~ 5-30 m• lengths 10 200 mm
– Continuous fiber: Continuous glass fiber
• diameters ~ 5-30 m• lengths, in effect, infinite
glass fiber
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
The remainder of this review (and ME450 as a whole!) is devoted to polymeric matrix
composites
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
Although originally developed for aerospace, the use of composites has expanded into many industriesof composites has expanded into many industries
AeroSpacep
MarineEnergy
Composite Materials and Technologies
Autos & Trucks
Infra-structure
Medical Recreation
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
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Overview:Aerospace applicationsAerospace applications
• Fiberglass introduced in 1930’s (originally used in tooling) and 1940’s (aircraft secondary structures)…
• Boron fibers introduced in the early 1960s…Gl (i d) b d id (K l ) fib• Glass (improved), carbon, and aramid (Kevlar) fibers introduced in the late 1960s and led to the increased use of advanced composites (particularly in military aircraft).
• Through the 1970s and early 1980s composite resins were brittle (e.g., “epoxy”), limiting (commercial) applications to secondary structural applicationssecondary structural applications.
• In the late 1980s resin toughening technologies were developed (e.g., “rubber-toughened epoxy”) paving the
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p ( g g p y ) p gway for the more extensive use of composites in primarystructural applications.
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Overview:Aerospace applicationsAerospace applications
• Boeing 777: Entered commercial service in 1995; – Composites account for about 10% of total structural weight– The graphite-epoxy empennage (i.e., the tail section) was the first
composite primary structure used in a Boeing commercial aircraftp p y g
• Boeing 787: Entered commercial service Sept 2010C i f 0% f l l i h– Composites account for >50% of total structural weight
– Features a graphite-epoxy fuselage, empennage, and wings– Uses ~20% less fuel than other aircraft of similar size, primarily due
to light-weight composite structure
• Boeing 777X: Enter commercial service in 2020 (?)
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g ( )– Composite wings…– Composite weight percent ?
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Overview:Commercial Transport AircraftCommercial Transport Aircraft
Use of composites in Boeing 727 (1963-84)
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Overview:Commercial Transport AircraftCommercial Transport Aircraft
Use of composites in Boeing 737 (1968-present; several models)
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Overview:Commercial Transport AircraftCommercial Transport Aircraft
Use of composites in Boeing 777 (1995-present; several models)
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Overview:Commercial Transport AircraftCommercial Transport Aircraft
Use of composites in Boeing 787 (Sept 2011; 3 models planned)
Other
Carbon laminateCarbon sandwich
Composites50%
Titanium15%
Steel10%
5%
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Other compositesAluminumTitanium Aluminum
20%
15%
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Overview:Commercial Transport AircraftCommercial Transport Aircraft
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Overview:Commercial Transport AircraftCommercial Transport Aircraft
Use of composites in Airbus 380 (2007-present; two models)
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Overview:Commercial Transport AircraftCommercial Transport Aircraft
Composites in the Airbus 350 (first commercial flight: 15 Jan 2015)
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Overview:Military AircraftMilitary Aircraft
…extensive use of composites in primary structures since 1970s
F/A-18 A/B (Hornet) first flew in 1976flew in 1976
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Overview:Military AircraftMilitary Aircraft
AV-8B (Harrier) first flew in 1978first flew in 1978
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Overview:Military AircraftMilitary Aircraft
Rotorcraft (typically helicopters) h d fib l bl d fhave used fiberglass blades for improved fatigue resistance for decades.
Other structural components now made from carbonnow made from carbon-epoxy to save weight and increase performance, as in the Comanche (above) andthe Comanche (above) and the Osprey (right)
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Overview:Space VehiclesSpace Vehicles
C it h b d t i l i b thComposites have been used extensively in both expendable and reuseable launch vehicles
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Overview:Space StructuresSpace Structures
Composites are used in the International Space Station
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Overview:Space StructuresSpace Structures
All-composite crew module for O i l ti hi l b iltOrion exploration vehicle built by NASA (engineering and tooling support from Janicki g ppIndustries)
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
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Overview:Marine ApplicationsMarine Applications
41′ Hunter Sailboat(www signature-yachts com)(www.signature-yachts.com)
147′ Gran Finale Yacht (www.deltamarine.com)
18′ 5″ Reinell Runabout ( i ll )(www.reinell.com)
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Overview:Marine ApplicationsMarine Applications
Hull, mast, & boom of the BMW-Oracle Racing , , gYacht produced using carbon-epoxy composites
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Overview:Marine ApplicationsMarine Applications
The 58-meter carbon fiber fixed wing-sail on the BMW Oracle AC33 trimaran is larger than a B-747 wing
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Overview:Automotive ApplicationsAutomotive Applications
Hi h d hi h f ’53 C tt f t dHigh-end, high-performance cars: ’53 Corvette featured composite body produced using fiberglass mat
http://auto howstuffworks com/corvette-pictures htmhttp://auto.howstuffworks.com/corvette-pictures.htm
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Overview:Automotive Applications
GM Corvette Z06 (2013 model shown)- Body: fiberglass woven fabric
H d idi ti l b fib
Automotive Applications
- Hood: unidirectional carbon fiber- Front wheelhouse: CMC* w/ glass
microspheres for weight reduction (1.1 Specific Gravity)p y)
- Floor boards: CMC* skins over ½” balsa wood core
- 2014: Body panels produced using new “pressure-press” equipment developedpressure press equipment developed by Globe Machine Manufacturing (Tacoma)
Fl B d
Front Wheelhouse
Floor Boards
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Overview:Automotive ApplicationsAutomotive Applications
The Lamborghini Aventador LP700-4 features many composite components, including a carbon fiber chassis produced using resin transfer molding (RTM)
// / ?http://www.netcomposites.com/newspic.asp?6674
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Overview:Automotive Applications
Advanced composites routinely used in high-performance race cars (Example: Honda F1 uses autoclave-cured carbon
Automotive Applications
race cars (Example: Honda F1 uses autoclave cured carbon composite chassis, suspension, wings, gear box, and engine cover)
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Overview:Automotive Applications
Composites in the UW FSAE Car steadily increased since 1990
Automotive Applications
Team 26 (2015)Team 1 (1990)cCar eCar
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Overview:Automotive Applications
• Extensive use of structural carbon composites in high-volume production vehicles (Chevy Malibu Ford Taurus
Automotive Applications
volume production vehicles (Chevy Malibu, Ford Taurus, Toyota Camry, etc) has been inhibited due to both high material costs and low production rates (resulting in high manufacturing costs)
• The Automotive Composites Alliance (ACA) tracks theThe Automotive Composites Alliance (ACA) tracks the use of composites in (relatively) high-volume production autos:
www.autocomposites.org/gallery/index.cfm
(….info may be dated…)
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Overview:Automotive ApplicationsAutomotive Applications
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Overview:Automotive Applications
I d f t t l it i d ti
Automotive Applications
• Increased use of structural composites in production vehicles beginning to occur due to:– Need for improved fuel efficiencies & lower emissionsNeed for improved fuel efficiencies & lower emissions– Changes in design philosophies (reduction in part count)– Improved manufacturing processes (i.e., increased
d ti t )production rates)– “Some” reduction in material costs
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Overview:Automotive Applications
SGL/Automotive Fiber Composites facility opened near Moses Lake in 2011(a joint venture with BMW) produces carbon fibers and
Automotive Applications
in 2011(a joint venture with BMW)…produces carbon fibers and fiber fabrics:
http://www.sglacf.com/en.html
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Overview:Applications in Heavy TrucksApplications in Heavy Trucks
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Overview:Advanced Composite MaterialsAdvanced Composite Materials
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Overview:Energy Applications: WindEnergy Applications: Wind• Windmills used for hundred of years
Man “o t of the bo ” concepts proposed to• Many “out of the box” concepts proposed to generate electricity (windmills wind turbines)
Photo sources:en.wikipedia.org/wiki/Windmills
iki di / iki/Wi d t bi #VAWT bten.wikipedia.org/wiki/Wind_turbine#VAWT_subtypeswww.buzzle.com/articles/wind-turbines-vertical-axis-wind-turbine.htmlthefraserdomain.typepad.com/energy/2006/04/turby_vertical_.html
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Overview:Energy Applications: Wind
• Most modern wind turbines based on horizontal axis and three composite blades
Energy Applications: Wind
axis and three composite blades• Commercially available wind turbines range from
those intended for home use...
200 W Air Breeze™www.windenergy.com
10 kW BWC EXCELwww.bergey.com
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Overview:Energy Applications: Wind…to those used in large wind farms that provide
power to entire communities
Energy Applications: Wind
power to entire communitiesStateline Wind Project, near Columbia Gorgenear Columbia Gorge, WA-OR border(www.rnp.org/Projects/stateline html)stateline.html)
Danish Horn RevDanish Horn Rev offshore windfarm (www.windpower.org/en/i t / ff h ht )pictures/offshore.htm)
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Overview:Energy Applications: WindEnergy Applications: Wind
Trend is towards very large turbines
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Overview:Energy Applications: Wind
• Composite blades traditionally produced using
Energy Applications: Wind
Composite blades traditionally produced using inexpensive fiberglass and wet-layup techniques
• As windmill sizes have increased new design drivers have emerged:
– Gravity/wind induced bending loads– Blade stiffness
Increasing use of advanced }
– Transportationcarbon fibers
}
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Overview:Energy Applications: Wind
Transportation issues…
Energy Applications: Wind
Fiberglass blades produced by LM Glasfiber (Germany); photoFiberglass blades produced by LM Glasfiber (Germany); photo courtesy of Dayton Griffin, Global Energy Concepts (Seattle, WA)
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Overview:Energy Applications: TidalEnergy Applications: Tidal
• In early stage of development…site evaluations underway i E C d d USin Europe, Canada, and US
• Several operating test sites in Europe (www.emec.org.uk)Several operating test sites in Europe (www.emec.org.uk)
• University of Washington is member of the Northwest N i l M i R bl E C (NNMERC)National Marine Renewable Energy Center (NNMERC) Seven potential sites in Puget Sound being evaluated:
http://depts washington edu/nnmrec/http://depts.washington.edu/nnmrec/
• Marine energy systems will likely utilize composites to minimize corrosion/maintenance issues
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Overview:Energy Applications: Tidal
What is optimal structural configuration?
Energy Applications: Tidal
A generator akin to an axial tube fan?(www.openhydro.com)
A generator akin to a windmill (or aircraft propeller)?(www marineturbines com)(www.marineturbines.com)
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Overview:Energy Applications: Tidal
Tidal energy farms envisionedEnergy Applications: Tidal
www.marineturbines.com
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Overview:Energy Applications: Tidal
Although optimal configuration TBD, composites ill t i l b d
Energy Applications: Tidal
will certainly be used
52 ft demonstration rotor made from glass and52 ft demonstration rotor made from glass and carbon fiber composites(www.marineturbines.com)
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Overview:Energy Applications: Deepwater Oil WellsEnergy Applications: Deepwater Oil Wells
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Overview:Energy Applications: Deepwater Oil Wells
Tension Leg PlatformsEnergy Applications: Deepwater Oil Wells
TethersContinuous or discontinuouscarbon fibres
3-5 mm rod 2-3” Strand
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Overview:Energy Applications: Deepwater Oil Wells
Shell’s Mars TLP (about 130
Energy Applications: Deepwater Oil Wells
Shell s Mars TLP (about 130 miles south of New Orleans, in Gulf of Mexico) uses 195 tons of composites- Water depth: 2940 ft (896 m)- Production began in 1996- Damaged by hurricane Katrina in 2005; no spill and sincein 2005; no spill and since repaired
- Designed to produce 220,000 barrels of oil/day and 220 M ft3gas/day
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Overview:Infrastructure applications
Composite pipes used in hydroelectric plants
Infrastructure applications
hydroelectric plants (www.amitech.com.b)
Light poles and transmission towerstransmission towers produced using composites(web grouprsi com/rsweb)(web.grouprsi.com/rsweb)
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Overview:Infrastructure applications
Composite electrical cables reduce weight and sag
Infrastructure applications
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Overview:Infrastructure applicationsInfrastructure applications
Column wraps for seismic retrofits and blast mitigation
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Overview:Infrastructure applicationsInfrastructure applications
Lining large dia piping(www.fibrwrapconstruction.com)Floor strengthening
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Overview:Infrastructure applicationsInfrastructure applications
Bridge cable stays(www.compositesworld.com/ct/( pissues/2006/February/1180)
Composite bridge decksComposite bridge decks(www.cobrae.org)
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Overview: Medical ApplicationsMedical Applications
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Overview:RecreationRecreation
The Rapture™ driver features a combination titanium and carbon/epoxy head and carbon/epoxyand carbon/epoxy shaft
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Overview:RecreationRecreation
Fishing poles
Skis & snowboards
Tennis rackets
Bicycle frames-wheels-rims
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Overview:RecreationRecreation
itwww.guitars.com
www.electricviolinshop.com www.tedbrewerviolins.com www.ifshinviolins.com
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Overview:RecreationRecreation
www.canbrass.com
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Overview:Specialty Applications
S b t i ti l
Specialty Applications
Subatomic particles are studied at Fermilab (outside Chicago)( g )
Protons and anti-protons race inprotons race in opposite directions around 6.4 km (4 mi) circular track at +99.99% the speed of light…and then collidelight…and then collide
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Overview:Specialty Applications
Resulting subatomic particles
Specialty Applications
created during the collision measured in several ways –one involves flat siliconone involves flat silicon detectors placed close to the collision point
Fermilab asked UW to design gand build a composite support structure to hold silicon detectors in position with greatdetectors in position with great precision
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Overview:Specialty ApplicationsSpecialty Applications
Composite support structure designed and built at UW
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Overview:Specialty ApplicationsSpecialty Applications
Sensor support end showing PEEK cooling tubes, foam spacers, and inner shell
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Overview:Specialty ApplicationsSpecialty Applications
Hybrid support end showing cooling manifold
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Overview:Specialty ApplicationsSpecialty Applications
Assembled structure and sensors in Fermilab test chamber
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Overview:Specialty ApplicationsSpecialty Applications
The complete collision detector
Insertion of instrumented UW composite structure into collision detector
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Overview:SummarySummary
• Three classes of Advanced Composite Materials: PMCs MMC CMCMMCs CMCs– All consist of a strong/stiff reinforcing material embedded in a
relatively weaker/compliant matrix material– ME450 is focused on PMCs– Particulate/whisker/short(chopped)/continuous PMCs
• Although originally developed for aerospace applications, PMCs are now used as load-bearing structural materials in many industriesmany industries