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Composites Manufacturing Fundamentals of Materials, Methods, and Applications Second Edition A. Brent Strong Society of Manufacturing Engineers Dearborn, Michigan
Copyright © 2008 Society of Manufacturing Engineers 987654321 All rights reserved, including those of translation. This book, or parts thereof, may not be reproduced by any means, including photocopying, scanning, digitizing, recording, or micro- filming, or by any information storage and retrieval system, without permission in writing of the copyright owners. No liability is assumed by the publisher with respect to use of informa- tion contained herein. While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions. Publication of any data in this book does not constitute a recommendation or endorsement of any patent, proprietary right, or product that may be involved. Library of Congress Catalog Card Number: 2007935302 International Standard Book Number (ISBN): 0-87263-854-5 ISBN 13: 978-087263854-9 Additional copies may be obtained by contacting: Society of Manufacturing Engineers Customer Service One SME Drive, P.O. Box 930 Dearborn, Michigan 48121 1-800-733-4763 www.sme.org/store SME staff who participated in producing this book: Rosemary Csizmadia, Senior Production Editor Steve Bollinger, Manager, Book & Video Publications Frank Bania, Cover Design Frances Kania, Administrative Coordinator Printed in the United States of America
THE PURPOSE OF THIS BOOK People entering the composites field need a way to learn the basics. Whether they are learning about composites in a college course or in the workplace, they need a simple text that gives enough detail to help with understanding. They also need a reference book that presents material in an easily understandable format. The first edition of this book has filled that need but is now over a decade old. This second edition describes advances that have been developed in the re- cent past, expands upon the explanations of the first edition to give further understand- ing, and adds key information that will serve as a reference for refreshing and expanding your knowledge of composites. THE IMPORTANCE OF MATERIALS IN COMPOSITES The field of composites is about materials and the way they are made into products. (In the aerospace world, this is called materials and processing or M&P.) Therefore, the first focus of this text is on materials. This is re- flected in several major chapters devoted to understanding the basic materials that are put together to create composite structures. Too often the materials side is viewed by composite engineers as merely a way to get data that will allow design calculations to be made. This text tries to simply and clearly present the details of why composite materi- als behave the way they do. Thus composites designers will gain an understanding of the causes of material performance and be able to choose from a wider set of acceptable ma- terials than might otherwise be possible. THE IMPORTANCE OF COMPOSITES MANUFACTURING Improving manufacturing technology is the greatest challenge today in the field of composites. When composites are cho- sen for an application principally because of their properties, it is natural that the manufacturing methods would be chosen to optimize those properties, even to the point where good manufacturing methods might be adversely affected. This practice has been evident in the aerospace industry where many composite parts have been made by processes that require high labor and costly techniques. Up to recent years, even large airplanes have been primarily hand-made. In some applications, the practice of prop- erty optimization will continue in spite of the problems that might arise in manufactur- ing. However, those in charge of manufac- turing have the challenge of improving the manufacturing process so that the quality of the performance of the part can be main- tained. Competitive pressures may also play a part to encourage reduction of costs through manufacturing improvements. These manufacturing improvements must be done while still maintaining or improving Fundamentals of Composites Manufacturing: Materials, Methods, and Applications xi Preface
xii Preface Fundamentals of Composites Manufacturing: Materials, Methods, and Applications part properties. Applications involving most advanced composites fit into this category. For other composite parts a different situ- ation occurs with respect to manufacturing. In these the choice of composites is based on both material performance and manu- facturing efficiencies. Parts made by these criteria are generally engineering composite products. In these parts the need to im- prove manufacturing is critically important because of the inevitable pressures of the marketplace for reduced costs and improved throughputs. Regardless of the situation, good initial choices about the type of manufacturing process used and then subsequent improve- ments to it are critically important. Too often the initial choice of manufacturing method is made based on previous experience or on available equipment. A rigorous method for evaluating the choice of manufacturing pro- cess is rarely used. Then, after the method is chosen, there is great reluctance to change it significantly. This is especially true in situations where the part and the manu- facturing process have been approved by a governmental agency or a major assembler like an airplane company. These products are locked into technologies that are diffi- cult to modify. However, as experience with long-term performance of composite parts grows and the data bases of composite prop- erties and designs increases, the reluctance to change manufacturing processes will decrease. Experience diminishes risk. The composites industry will continue struggling to cope with the requirements for superb mechanical properties and the need for economical manufacturing methods. The manufacturing side is changing rapidly and a premium is being placed on the innovative individual. Manufacturing technologies have been borrowed from many other industries. From plastics came the concepts used in resin curing, composites molding, extrusion, and finishing. From metals came ideas in cast- ing, forming, and mold making. Some of the reinforcement products are, of course, from the textile industry but other concepts include textile fiber handling, cloth pattern cutting, and lay-up. A broad spectrum of en- gineering disciplines has contributed—from bridge building to laser cutting. Insight and innovation are key elements to prog- ress and success in the field of composites manufacturing. FEATURES OF THE BOOK For classroom use or individual reading, the book contains many features to make learning easier. 1. Each chapter begins with an overview of the key points to be addressed. The order of the chapter follows the order of the overview so that you can see what is in the chapter and easily find it. 2. Each chapter contains a case study dis- cussing a specific application of one or more principles taught in the chapter. 3. A summary is given in each chapter so that the key learning points can be reviewed. 4. For assistance to college professors, each chapter has a laboratory experi- ment dealing with the concepts of that chapter. 5. A set of questions is given in each chapter so that individuals can assess learning and professors can use them in preparing questions for exams. 6. A bibliography details additional read- ing for each chapter. 7. A glossary of important terms is found at the back of book to assist in under- standing or remembering terms given in the book. Each of the terms defined in the glossary is marked in bold print the first time it is used in the text.