Imst Composites 23 Jul09 Final
- 1. Institute for Maintenance Science and TechnologyComposites sustainmentDr. Stephen Hudak, Joseph Heil, Jim Fuss, Dr. Jerry CuomoMaterials Science and Engineeringwww.imst.usNCSU Composites SymposiumJuly 23, 2009
- 2. OutlineIntroduce IMSTComposite Sustainment ActivitiesProject Specific ExamplesCarbon Fiber Recycling2
- 3. IMST MissionPromote economic development in the State of North Carolina by leveraging the resources of NC State University to enable partnerships among industry, the military, and the University and Community College Systems.3
- 4. IMSTCAMP-M; IMST Founded in 2005 by:Dr. Jerry Cuomo, Dr. Roger Sanwald & Dr. John Strenkowski19 research engineers, scientists, & associates10 graduate students13 undergraduate students4
- 5. Composites Sustainment ActivitiesReverse EngineeringRepair TechnologiesEconomic DevelopmentTraining ActivityNDIAtmospheric PlasmaTechnical SupportCarbon Fiber RecyclingComposites Manufacturing5
- 6. PartnersNavair – Paxutent RiverCherry Point, North Island, JacksonvilleCoast Guard – Elizabeth CityDRS Technical ServicesBoeing - St. Louis, Seattle, Philadelphia, Mesa, TacomaAFRL - DaytonALC - Hill, Ogden, Warner RobbinsNavsea – CaderockARL – RDECOMCommunity Colleges - Lenoir, Craven6
- 7. IMST Case Study:Composite Part Reverse EngineeringProblem: Composite helicopter fairing has no blueprint available or manufacturerINDUSTRYPARTNERSEXTERNALPARTNERSNC Military BusinessCenterSISMartinMariettaCompositesNAVAIRCherryPointIMSTVXAerospace.NCSU College of TextilesWesternCarolinaUniv.NCSU MSEProblem Solving Methodology: Materials Analysis
- 13. Technical Data PackageNCSUA.I.F.UNC SYSTEM RESOURCESNCSU RESOURCESConclusionReplacement fairing is provided to the Navy that will be manufactured by NC company7
- 14. Composites RepairField Deployable Repair ImprovementsFastener Hole RepairRapid Manufacturing of Secondary StructuresAdhesive Shelf Life ExtensionAdhesive Field TestsHeat Damage Detection & QuantificationQuick Curing Adhesives8
- 15. NDIFlash ThermographyVibration MEMSIR Thermography (Veracity)Ultrasonic'sAcousto-UltrasonicImpedance SpectroscopyEmbedded SensorsFiber-opticsMagnetic coated wires9
- 16. Flash Thermography10Steven M. ShepardThermal Wave Imaging, Inc.845 Livernois, Ferndale, MI [email protected]
- 17. Flash Thermography11Steven M. ShepardThermal Wave Imaging, Inc.845 Livernois, Ferndale, MI [email protected]
- 18. Atmospheric PlasmaTreatedUntreated5 SecondTreatmentTreated5 SecondTreatmentAtmospheric Plasma Treatment:
- 19. Produces a highly oxidizing atmosphere.
- 21. Polymer surface chemistry altered.
- 22. Produces a Hydrophilic/Oleophilic surface.
- 23. Result:
- 24. Improved adhesion between resin and fibers.12
- 25. Plasma Paint RemovalMIL85285 Paint stack on AluminumBeforeAfter PlasmaMIL 83282Hydraulic FluidMineral Oil/DyeWater/Dye13
- 26. Surface Changes After Plasma TreatmentBeforeAfterHydraulic Fluid – Methanol - WaterHydraulic Fluid – Methanol - WaterFluorescent Dye in Hydraulic Fluid14
- 27. Plasma Removal of Hydraulic FluidMaterial Calibration Setting
- 28. Damage Factor %
- 29. CorrelationBaselineUntreated Sample 3LIF Indicates Matrix Undamaged. ATR indicates that Hydraulic Fluid was Removed Plasma Light Etch Sample 3LIF & ExoScan (FTIR)Analysis IndicatesMatrix and fluidPlasma Treated Sample 215
- 30. Rotor Blade Paint Removal using Atmospheric PlasmaPlasma Partial RemovalPlasma Complete Removal16
- 31. Sealant Removed for Maintenance AccessBeforeAfter17
- 32. Removal of Various Coatings from Different Substrates Removal to PrimerUntreated AreaUntreated SealantRemoved to SubstrateRadomeAl HoneycombRAM on CFE18
- 33. Boeing Carbon Fiber Recycling19Five Year relation with Boeing in Seattle
- 34. 4 papers
- 35. 3 conferences
- 36. $100K in 2008 & 2009
- 37. Why Recycle?
- 38. 50% by weight is discarded as manufacturing scrap
- 40. Limited supplyFiber HistoryEnd of Life Parts – Shredded and Sorted at Huron Valley Fritz West in Tucson, ArizonaReclamation of Fiber by Recycled Carbon Fiber LLC Birmingham U.K 350˚F Cure Epoxy with AS4 FiberControl Unsized AS4Reclamation of Fiber by Adherent Technologies Albuquerque, NM Characterizationby NC State with Direction and Oversight by Boeing 20
- 41. Recycled Carbon Fiber CompositesTest panels made using the bulk molding process.21Wet lay process for making randomly oriented mats.
- 42. Composites Testing22Glass Transition by DMAASTM D 7028 Standard Method for Tg of Polymer Matrix Composites
- 43. SummaryIMST is actively engaged with composite sustainment for Aerospace applicationsEducation is a core component of activityStarted SAMPE chapterIMST is customer focusedNCSU partnerships and projects continue to growNorth Carolina is becoming an aerospace technology corridor23
- 44. RCF Mechanical PropertiesRecycled Carbon Fiber, LLCAS4: 435ksi Tensile Strength (20mm GL)AS4: 325msi Modulus (20mm GL)T800s: 385ksi (60mm GL)T800s: 490msi ModulusANEA/ KarborekT800s: 500ksi Tensile Strength (60mm GL)T800s: 430msi Modulus (60mm GL)24