Volume 21 - Composites Part 10 pdf

Introduction to Post-Processing and Assembly Introduction Introduction to Post-Processing and Assembly Flake C. Campbell, The Boeing Company Polymer-Matrix Composites Introduction to Post-Processing and Assembly Flake C. Campbell, The Boeing Company Metal-Matrix and Ceramic-Matrix Composites Machining, Trimming, and Routing of Polymer- Matrix Composites Introduction Machining, Trimming, and Routing of Polymer-Matrix Composites Lawrence F. Kuberski, Fischer U.S.A. Machining Operations • • μ Machining, Trimming, and Routing of Polymer-Matrix Composites Lawrence F. Kuberski, Fischer U.S.A. Cutting Tools For Machining Fig. 1 Typical diamond brazed cutting tool Fig. 2 Solid carbide end mill with thin film diamond coating Machining, Trimming, and Routing of Polymer-Matrix Composites Lawrence F. Kuberski, Fischer U.S.A. Peripheral Milling Fig. 3 Typical machined surface of carbon/epoxy composite Machining, Trimming, and Routing of Polymer-Matrix Composites Lawrence F. Kuberski, Fischer U.S.A. Face Milling Table 1 Typical face-milling parameters for carbon fiber-reinforced epoxy composites Tool diam Speed (a) Axial depth of cut Radial depth of cut Feed rate mm in. m/min sfm mm in. mm in. mm/min in./min • • • • • • Machining, Trimming, and Routing of Polymer-Matrix Composites Lawrence F. Kuberski, Fischer U.S.A. Trimming μ Material thickness Feed rate mm in. mm/min in./min ≤ 50–70 50–70 25.4–50.8 1–2 127–152 5–6 50–70 Fig. 4 Typical abrasive waterjet head configuration Fig. 5 Waterjet cutting Table 2 Partial list of materials cut with abrasive waterjet 718 Inconel 625 Inconel 6AL-4V titanium alloy (3.2 mm, or 0.125 in., thick) Commercially pure titanium Hastelloy 321 CRES (75 mm, or 3 in., thick) 15-7 PH CRES 301 half hard CRES 301 full hard CRES Chromoloy ESCO 49M-high nickel/high chrome alloy (170 mm, or 6.75 in., thick) Mild steels Glass (25 mm, or 1 in., thick) Aluminum (140 mm, or 5.5 in., thick) Peel shim stock 304L CRES (13 mm, or 0.5 in., thick) Metal matrix Graphite Aramid Glass Laminated glass Ceramics Fig. 6 Typical router bit Machining, Trimming, and Routing of Polymer-Matrix Composites Lawrence F. Kuberski, Fischer U.S.A. Selected References • [...]... Machined honeycomb parts Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Syntactic Core Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Foam Core Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Adhesive-Bonding Process μ... Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Sandwich Structures Fig 11 Components of a honeycomb panel Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Honeycomb Core Fig 12 Corrosion-resistant honeycomb core Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St... 15 Prefit fixture used for a complex-contour aircraft door Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Adhesive Application Fig 16 Robot used for spraying adhesive Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Tooling • • • • Fig 17 Press-bonding fixture Fig 18 Detail of a pressure... when bonded to metal τ Fig 10 Various bonded joint configurations (a), (b), and (c) Shear (d) Scarf (e) Tension (f) Peel References cited in this section Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Epoxy Adhesives Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Surface Preparation... Phenolicbased One -part films 163–177 (325– 350) To 177 (350) Hightemperature use High cost; low peel strength; high cure and postcure temperatures; volatiles for some forms Low peel strength Table 2 Use-temperature guide to structural adhesives Adhesive –253 (– –196 (– –73 (– –54 (– Room 82 423) 320) 100 ) 65) (180) 149 (300) 216 (420) … Acrylics … … … L/P H/E Secondary Adhesive Bonding of Polymer-Matrix Composites. ..• • • • • • • Secondary Adhesive Bonding of Polymer-Matrix Composites Introduction Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Adhesive Joint Design Fig 1 Typical secondary adhesively bonded joint configurations (a) Single lap joint (b) Tapered single... Secondary Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Selection Criteria • • • • • • • • • • • • • • • • • • • • Table 1 Typical characteristics of adhesive types Type Form Cure temperature,°C (°F) Maximum use temperature,°C (°F) Advantages Not generally as strong or environmentally resistant as typical heat-cured epoxies Store at 18 °C (0 °F);... Adhesive Bonding of Polymer-Matrix Composites Flake C Campbell, The Boeing Company&# 8212 ;St Louis Highly Loaded Joint Considerations Fig 4 Single lap shear specimen P, load M/G L/P … … G … … … L/G … … Fig 5 KGR-1 extensometer with thick adherend specimen Source: Ref 1 Fig 6 Adhesive shear stress distribution for skin-doubler specimen E, tensile modulus of adherends; G, shear modulus of adhesive Source: . Company Metal-Matrix and Ceramic-Matrix Composites Machining, Trimming, and Routing of Polymer- Matrix Composites Introduction Machining, Trimming, and Routing of Polymer-Matrix Composites Lawrence. Introduction to Post-Processing and Assembly Introduction Introduction to Post-Processing and Assembly Flake C. Campbell, The Boeing Company Polymer-Matrix Composites Introduction to Post-Processing. temperatures; volatiles for some forms Phenolic- based One -part films 163–177 (325– 350) To 177 (350) High- temperature use Low peel strength Table 2 Use-temperature guide to structural adhesives