Fatigue and Aeronautic Materials Research Group Process and Characterization of Composite by RTM

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Nathan Quintanilha Pereira
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1 Process and Characterization of Composite by RTM Maria Odila Hilário Cioffi 1

2 2

3 18 Researchers 21 Students 1 Technician 3

4 Project General Objectives: Development of an experimental methodology to produce aeronautical components by resin transfer molding process; Substitution of Al7050- T7451 alloy by noncrimp fabric (NCF)/epoxy system (RTM6) composites; HYDRAULIC CYLINDERS SHAFT STALK SHOCK ABSORBER EMBRAER Landing Gear 4

Substitution of Al7050- T7451 alloy by noncrimp fabric (NCF)/epoxy system

5 Project General Objectives: Development of an experimental methodology to produce aeronautical components by resin transfer molding process; Substitution of Al7050- T7451 alloy by noncrimp fabric (NCF)/epoxy system (RTM6) composites; HYDRAULIC CYLINDERS SHAFT STALK SHOCK ABSORBER EMBRAER Landing Gear 5

6 Project General Objectives: Development of an experimental methodology to produce aeronautical Properties components by resin transfer molding process; Substitution of Al7050- T7451 alloy by noncrimp fabric (NCF)/epoxy system (RTM6) composites; HYDRAULIC CYLINDERS SHAFT Al 7050-T7451 STALK Materials SHOCK ABSORBER NC2/RTM6 Elastic Modulus 65 GPa 60 GPa Yield Strength 429 MPa 530 MPa Ultimate Tensile Strength 502 MPa 665 MPa Elongation 10 % 2 % EMBRAER Landing Gear 6

7 Project General Objectives: Development of an experimental methodology to produce aeronautical Properties components by resin transfer molding process; Substitution of Al7050- T7451 alloy by noncrimp fabric (NCF)/epoxy system (RTM6) composites; HYDRAULIC CYLINDERS SHAFT Al 7050-T7451 Materials SHOCK ABSORBER NC2/RTM6 Elastic Modulus 65 GPa 60 GPa STALK Materials change will provide a reduction Yield Strength 429 MPa 530 MPa of 59% weight for the component. Ultimate Tensile Strength 502 MPa 665 MPa Elongation 10 % 2 % EMBRAER Landing Gear 7

8 Stress (MPa) Results Fatigue Tests Delamination Rupture N (cycles) SxN Curve. NC2/RTM6Composite. 8

9 Stress (MPa) Results Fatigue Tests cusps 440 hackles Delamination Rupture N (cycles) SxN Curve. NC2/RTM6Composite. 9

10 Process Matrix Toughness Kinetic Study Reinforcement Stitching Drapability Permeability Process Process Parameters influence Cure cycle Composites Acoustic inspection Microscopy 10

11 Matrix Toughness: Impregnation Map of NCF/RTM6 composite 3-D construction C-scan Map: NCF/RTM6 composite 11

12 Matrix Toughness: Impregnation Map of NCF/RTM6 composite 3-D construction C-scan Map: NCF/RTM6 composite 12

13 Matrix Toughness: HPBA polymer was more efficient due to molecule higher free volume and suitable physical interaction with epoxy system Sea-island 13

14 Matrix Kinetic reaction Prism EP2400 Dynamic DSC for 2, 5 e 10 C Isothermal coversion Curve Dynamic DSC for different heating rates; Simulation of isothermals by isoconversional method; The difference between the theoretic and experimental method is associated by autocatalytic and n order kinetic reactions 14

15 Matrix kinetic study Prism EP2400 Experimental curves of rate and isothermal conversion at 170, 175 e 180ºC. Time function fitting experimental curve Conversion rates by DSC autocatalytic model until 50 min for T cura. As the cure progress n order model. 15

homogeneous stitching Higher fatigue behavior was observed

16 Stitching Stitching influence Chain Stitching Tricot Stitching Chain showed a fatigue behavior more uniforme due to the homogeneous stitching Higher fatigue behavior was observed when the stitching was tricot but with premature delaminatin process 16

17 Stitching Stitching influence Chain Stitching Tricot Stitching Chain showed a fatigue behavior more uniforme due to the homogeneous stitching Higher fatigue behavior was observed when the stitching was tricot but with premature delaminatin process 17

18 Reinforcement Drapability 18

19 Reinforcement Drapability 19

20 Reinforcement Drapability 20

21 Reinforcement Drapability 21

22 Reinforcement Drapability 22

23 Reinforcement Permeability: experimental X Simulation It was also observed the race tracking phenomena for both model and experimental 23

24 Reinforcement Permeability: experimental X Simulation The same resin front behavior was observed for both until 2/3 fabric length. 24

25 Reinforcement Permeability: experimental X Simulation From this point the fluid become different. 25

26 Reinforcement Permeability: experimental X Simulation At the end of the fabric length the front is equal again. The simulation and the mesh model are suitable 26

27 Reinforcement Permeability: experimental X Simulation Total time of injection t = 2342 s (model 4747 elements). Permeability study t = 1137 s. 27

28 RTM Process FAPESP processo número 2006/ JP 28

29 Process RTM Process parameter influence: Temperature: Enough to reduce the resin viscosity in order to promote high volume fiber impregnation; High Viscosity produce fiber misalignment. Pressure: Enough to improve the impregnation ( bar); Excessive pressure produce fiber misalignment. Fiber volume fraction: Constant throughout the laminate in order to avoid preferential resin path, which cause dry spots. 29

30 RTM Process Cure cycle: Set by kinetic study ; low temperature rate improves the fabric impregnation; longer periods of low viscosity resin within the first 25 min 50 mpa.s 30

31 Composite Procedure for acoustic microscopy inspection - MIScan Ultrasonic inspection A-scan and C-scan method Transducer 10 MHz probe Pulse-echo mode Equipment Model PSS-600, MUIS32 manufactured by MATEC A-scan graphic aided to calibrate the patterns of typical composite peaks 31

MHz probe Pulse-echo mode Equipment Model PSS-600, MUIS32

23 Efeito de race-tracking detectado no ultrassom: a) gate 1;

32 Composite Procedure for acoustic microscopy inspection - MIScan Ultrasonic inspection A-scan and C-scan method Transducer 10 MHz probe Pulse-echo mode Equipment Model PSS-600, MUIS32 manufactured by MATEC a) INJEÇÃO b) INJEÇÃO Figura 6.23 Efeito de race-tracking detectado no ultrassom: a) gate 1; b) gate 2 A-scan graphic aided to calibrate the patterns of typical composite peaks 32

b) Equipment Model PSS-600, MUIS32 manufactured by MATEC a) INJEÇÃO INJEÇÃO

33 Composite Procedure for acoustic microscopy inspection - MIScan Ultrasonic inspection A-scan and C-scan method Transducer 10 MHz probe Pulse-echo mode b) Equipment Model PSS-600, MUIS32 manufactured by MATEC a) INJEÇÃO INJEÇÃO a) A-scan graphic aided to calibrate the patterns of typical composite peaks 33

Research Interlaminar Fracture Toughness Study Advanced Composites

composite fatigue life prediction considering DMA results

composite Composites development to historic edification application

34 Research Interlaminar Fracture Toughness Study Advanced Composites Crack propagation in 5HS carbon/epoxy composites Structural composite fatigue life prediction considering DMA results Developments Thermossseting composites by RTM process Natural composite Composites development to historic edification application Thermoplastics composites obtained by injection Nanobiodegradable composites by electrospinning 34

35 Projects RTM linked projects

36 Projetos CNPq n / FAPESP nº 2006/ Aquisição dos seguintes equipamentos: Injetora Radius 2100cc RTM Molde fechado em aço Sistema de aquecimento via resistências elétricas Bomba de vácuo Microscópio de varredura acústica (MIScan) Estufa a vácuo, agitadores e balança analítica

37 Projetos Figura XX: Sistema de processamento de compósitos por RTM locado no DMT/FEG/UNESP

38 Projetos Figura XX: Detalhes do molde em aço usando no processamento via RTM

39 Projetos Figura XX: : Equipamento de ultrassom por imersão em água locado no DMT/FEG/UNESP

40 Projetos CNPq n / Titulo do Projeto: PROCESSAMENTO DE COMPÓSITOS VIA RTM: CONTROLE DE VAZIOS POR DIFERENTES METODOLOGIAS Aquisição dos seguintes equipamentos: Porosímetro Automático de Mercúrio, modelo Poremaster 33 GT (Quantachrome Instruments) Descrição: Realiza medições de tamanho de poros de distribuição em duas amostras de geração de pressão contínua ou gradual de vácuo para psi.

41 Projetos Figura XX: Porosímetro Automático de Mercúrio locado no DMT/FEG/UNESP

42 Projetos CNPq n / Titulo do Projeto: PROCESSAMENTO DE COMPÓSITOS VIA RTM: CONTROLE DE VAZIOS POR DIFERENTES METODOLOGIAS Aquisição dos seguintes equipamentos: Analisador de Densidade Real, Modelo UltraFoam 1200e (Quantachrome Instruments) Descrição: Determina o volume real/densidade de sólidos.

43 Projetos Figura XX: Analisador de Densidade Real locado no DMT/FEG/UNESP

44 Projetos CNPq n / Titulo do Projeto: PROCESSAMENTO DE COMPÓSITOS VIA RTM: CONTROLE DE VAZIOS POR DIFERENTES METODOLOGIAS Aquisição dos seguintes equipamentos: Cortadeira Metalográfica TechCut-5 (Allied High Tech Products) Descrição: Cortadeira metalográfica com avanço automático.

45 Projetos Figura XX: Cortadeira metalográfica locada no DMT/FEG/UNESP

46 Projetos CNPq n / Titulo do Projeto: PROCESSAMENTO DE COMPÓSITOS VIA RTM: CARACTERIZAÇÃO TÉRMICA Aquisição do seguinte equipamento: Equipamento de Calorimetria Exploratória Diferencial (DSC) com compensação de potência, modelo DSC 8000 (PerkinElmer) Descrição: Esse equipamento tem a capacidade de operar em uma faixa de temperatura de trabalho de -180ºC até 750ºC com taxas de aquecimento e resfriamento de 1 a 750ºC/min.

47 Projetos Figura XX: DSC 8000 (equipamento em fase de importação)

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