TERM PAPER OF MATERIAL SCIENCE TOPIC: NOTE ON CARBON COMPOSITE MATERIALS AND ITS USES IN SPACE SHUTTLES

SUBMITTED TO: Mr. GURVTAR SINGH Sir, MEC208.

SUBMITTED BY: THANGELLA NAGENDRA BABU, Regd. No:11013535, ROLL NO:B60, Section:M1R11.

ACKNOWLEDGEMENT

I hereby declare that the term paper that I have been allotted by our corresponding lecturer is done with great sincere and dedication. I have taken help from the internet for clear information on my topic and also some reference manufacturing industrial websites. I would like to thank my lecturer Mr.Guravtar Singh who have helped me through my term paper and I would also like to thank my roommates and friends through my subjective doubts on my term paper.And I would also like to thank my parents for their support. Finally I would like thank the my almighty for his blessings.

Thangella Nagendra Babu , 11013535.

TABLE OF CONTENTS
1.GENERAL DEFINITION 2.DEFINITION 3.OVERVIEW OF COMPOSITES 4.CONSTITUENTS OF COMPOSITES i. Matrixes ii. Resins iii. Reinforcement 5.VARIOUS MOULDING PROCESSES USED FOR MAKING COMPOSITES 1. Vacuum bag moulding 2. Pressure bag moulding 3. Autoclave moulding 4. Resin transfer moulding 6.ADVANCED COMPOSITE MATERIALS 7.DIFFERENT TYPES OF ADVANCED COMPOSITES 8.GENERAL PROPERTIES OF ALL TYPES OF COMPOSITES 9.CARBON COMPOSITE MATERIALS 10.USES OF CARBON COMPOSITES IN AEROSPACE AND SPACE SHUTTLES 11.CONCLUSION 12.REFERENCES

Carbon Composite material used in space shuttles

General Definition: Composites or composite materials are used more and more for primary structures in commercial,aerospace, industrial, marine, and recreational structures.composites consist of fibrous reinforcements bonded together with matrix material and these are generally found in our bones,in wood,horns etc. These even allow the stiffness and strength of material with change in direction of loading.

Definition:
Composite materials are either engineered or naturally occurring materials made from two or more constituent materials with significantly different physical or chemical properties which remain separate and distinct at the macroscopic or microscopic scale within the finished structure. These are often shortened to composites or called composition materials. A common example of a composite would be disc brake pads, which consist of hard ceramic particles embedded in soft metal matrix. The most advanced examples are performed on spacecraft in demanding environments. Composite materials consist of strong fibres such as glass or carbon set in a matrix of plastic or epoxy resin, which is mechanically and chemically protective. The fibres may be continuous or discontinuous but possess a strength very much greater than that of the same bulk materials. For example, carbon fibres have a tensile strength of the order of 2400 N/mm2 and a modulus of elasticity of 400 000 N/mm2. A sheet of fibre-reinforced material is anisotropic, that is, its properties depend on the direction of the fibres. Generally, therefore, in structural form two or more sheets are sandwiched together to form a lay-up so that the fibre directions match those of major loads.

Fig.Materials used in construction of aircraft or space shuttle

Overview of Composites: Composites are made up of individual materials referred to as constituent materials. There are two categories of constituent materials: matrix and reinforcement. At least one portion of each type is required. The matrix material surrounds and supports the reinforcement materials by maintaining their relative positions. The reinforcements impart their special mechanical and physical properties to enhance the matrix properties. A synergism produces material properties unavailable from the individual constituent materials, while the wide variety of matrix and strengthening materials allows the designer of the product or structure to choose an optimum combination. Composites are materials that are combinations of two or more organic or inorganic components. One material serves as a "matrix," which is the material that holds everything together, while the other material serves as reinforcement, in the form of fibers embedded in the matrix. Until recently, the most common matrix materials were "thermosetting" materials such as epoxy, bismaleimide, or polyimide. The reinforcing materials can be glass fiber, boron fiber, carbon fiber, or other more exotic mixtures. Let us first discuss generally about composites like their composites,how they are prepared,their general properties and about the advanced composite materials. Constituents of composites: Generally the composites contains matrixes,resins,reinforcement that generally give specific properties that required as per the requirement. 1.Matrixes: The common matrixes are generally used are mud,cement(concrete),polymers(fibre reinforced plastics),metals and ceramics. 2.Resins: Typically, most common polymer-based composite materials, including fiberglass, carbon fiber, and Kevlar, include at least two parts, the substrate and the resin. Polyester resin tends to have yellowish tint, and is suitable for most backyard projects. Its weaknesses are that it is UV sensitive and can tend to degrade over time, and thus generally is also coated to help preserve it. It is often used in the making of surfboards and for marine applications. Epoxy resin is almost totally transparent when cured. In the aerospace industry, epoxy is used as a structural matrix material or as a structural glue.Shape memory polymer (SMP) resins have varying visual characteristics depending on their formulation. These resins may be epoxy-based, which can be used for auto body and outdoor equipment repairs; cyanate-ester-based, which are used in space applications; and acrylate-based, which can be used in very cold temperature applications, such as for sensors that indicate whether perishable goods have warmed above a certain maximum temperature.The advantage of shape memory polymer resins is that they can be shaped and reshaped repeatedly without losing their material properties, and these resins can be used in fabricating shape memory composites. 3.Reinforcement: The addition of high strength fibers to a polymer matrix can greatly improve mechanical properties such as ultimate tensile strength, flexural modulus, and temperature resistance. Fiber-reinforced composite materials can be divided into two main categories normally referred to as short fiber-reinforced materials and continuous fiber-reinforced materials. Continuous reinforced materials will often constitute a layered or laminated structure. The short and long fibers are typically employed in compression moulding and sheet moulding operations. Moulding methods employed for composites: A variety of moulding methods can be used according to the end-item design requirements. The principal factors impacting the methodology are the natures of the chosen matrix and reinforcement materials. Another important factor is the gross quantity of material to be produced.

1.Vacuum bag moulding: A process using a two-sided mould set that shapes both surfaces of the panel. On the lower side is a rigid mould and on the upper side is a flexible membrane or vacuum bag. The flexible membrane can be a reusable silicone material or an extruded polymer film. Then, vacuum is applied to the mould cavity. This process can be performed at either ambient or elevated temperature with ambient atmospheric pressure acting upon the vacuum bag. Most economical way is using a venturi vacuum and air compressor or a vacuum pump. 2.Pressure bag moulding: This process is related to vacuum bag moulding in exactly the same way as it sounds. A solid female mould is used along with a flexible male mould. The reinforcement is placed inside the female mould with just enough resin to allow the fabric to stick in place (wet lay up). A measured amount of resin is then liberally brushed indiscriminately into the mould and the mould is then clamped to a machine that contains the male flexible mould. The flexible male membrane is then inflated with heated compressed air or possibly steam. The female mould can also be heated. Excess resin is forced out along with trapped air. This process is extensively used in the production of composite helmets due to the lower cost of unskilled labor. 3.Autoclave Moulding: A process using a two-sided mould set that forms both surfaces of the panel. On the lower side is a rigid mould and on the upper side is a flexible membrane made from silicone or an extruded polymer film such as nylon. Reinforcement materials can be placed manually or robotically. They include continuous fibre forms fashioned into textile constructions. Most often, they are pre-impregnated with the resin in the form of prepreg fabrics or unidirectional tapes. In some instances, a resin film is placed upon the lower mould and dry reinforcement is placed above. The upper mould is installed and vacuum is applied to the mould cavity. The assembly is placed into an autoclave. This process is generally performed at both elevated pressure and elevated temperature. The use of elevated pressure facilitates a high fibre volume fraction and low void content for maximum structural efficiency. 4.Resin Transfer Moulding: A process using a two-sided mould set that forms both surfaces of the panel. The lower side is a rigid mould. The upper side can be a rigid or flexible mould. Flexible moulds can be made from composite materials, silicone or extruded polymer films such as nylon. The two sides fit together to produce a mould cavity. The distinguishing feature of resin transfer moulding is that the reinforcement materials are placed into this cavity and the mould set is closed prior to the introduction of matrix material. Resin transfer moulding includes numerous varieties which differ in the mechanics of how the resin is introduced to the reinforcement in the mould cavity. Several other moulding processes along with the above stated moulding processes are generally employed to develop composite materials. There are several other composite materials used for specific uses which are like preparing special hat resistive parts to the aeroplanes,space shuttles.

Advanced composite materials: Advanced composite materials (ACMs) are also known as Advanced polymer matrix composites. These are generally characterized or determined by unusually high strength fibres with unusually high stiffness, or modulus of elasticity characteristics, compared to other materials, while bound together by weaker matrices. These are termed advanced composite materials (ACM) in comparison to the composite materials commonly in use such as reinforced concrete, or even concrete itself. The high strength fibers are also low density while occupying a large fraction of the volume. Advanced composites exhibit desirable physical and chemical properties that include light weight coupled with high stiffness (elasticity), and strength along the direction of the reinforcing fiber, dimensional stability, temperature and chemical resistance, flex performance, and relatively easy processing. Advanced composites are replacing metal components in many uses, particularly in the aerospace industry.

Basic types of advanced composites: Advanced composite systems are divided into two basic types, thermosets and thermoplastics. Thermosets are by far the predominant type in use today. Thermosets are subdivided into several resin systems including epoxies, phenolics, polyurethanes, and polyimides. Thermosets: Thermoset resins require addition of a curing agent or hardener and impregnation onto a reinforcing material, followed by a curing step to produce a cured or finished part. Once cured, the part cannot be changed or reformed except for finishing. Some of the more common thermosets include epoxies, polyurethanes, phenolic and amino resins, bismaleimides (BMI, polyimides), polyamides. Of these, epoxies are the most commonly used in the industry. Epoxy resins have been in use in U.S. industry for over 40 years. Epoxy compounds are also referred to as glycidyl compounds. The epoxy molecule can also be expanded or cross-linked with other molecules to form a wide variety of resin products, each with distinct performance characteristics. These resins range from low-viscosity liquids to high-molecular weight solids. Typically they are high-viscosity liquids. The second of the essential ingredients of an advanced composite system is the curing agent or hardener. These compounds are very important because they control the reaction rate and determine the performance characteristics of the finished part. Since these compounds act as catalysts for the reaction, they must contain active sites on their molecules. Some of the most commonly used curing agents in the advanced composite industry are the aromatic amines. Two of the most common are methylene-dianiline (MDA) and sulfonyldianiline (DDS). Thermoplastics: Thermoplastics currently represent a relatively small part of the ACM industry. They are typically supplied as nonreactive solids (no chemical reaction occurs during processing) and require only heat and pressure to form the finished part. Unlike the thermosets, the thermoplastics can usually be reheated and reformed into another shape, if desired. General Properties Of all types of Composites: 1.The composite materials possess High strength which is major requirement satisfied for all industrial and aerospace purposes. 2.Composites also have High stiffness. 3.These composites have Low density and light weight. 4.Composites possess good shear properties. 5.Composites have high damage tolerance. 6.But these composites are very difficult to control the manufacturing defects during its production. 7.These composites have very high corrosion resistance and fatigue resistance. 8.These composites require less cost for its assembly purposes.

Carbon composite materials: These composites have now been replaced by carbon fibre reinforced plastics (CFRP), which have similar properties to boron composites but are very much cheaper. Typically, CFRP has a modulus of the order of three times that of GRP, one and a half times that of a Kevlar composite and twice that of aluminium alloy. Its strength is three times that of aluminium alloy, approximately the same as that of GRP, and slightly less than that of Kevlar composites. Aerospace CFRP does, however, suffer from some disadvantages. It is a brittle material and therefore does not yield plastically in regions of high stress concentration. Its strength is reduced by impact damage which may not be visible and the epoxy resin matrices can absorb moisture over a long period which reduces its matrix dependent properties, such as its compressive strength; this effect increases with increase of temperature. Further, the properties of CFRP are subject to more random variation than those of metals. All these factors must be allowed for in design. On the other hand, the stiffness of CFRP is much less affected than its strength by the above and it is less prone to fatigue damage than metals. It is estimated that replacing 40% of an aluminium alloy structure by CFRP would result in a 12% saving in total structural weight. Use of Cabon Composites in various fields: 1.Aircraft brakes: Our Materials are already in use on some of the world's most well-known aircraft.We have been manufacturing Carbon/Carbon (C/C) brake materials from their initial development on high performance military aircraft through the wide spread acceptance on commercial aircraft. Our C/C materials are qualified on a number of military and commercial aircraft. Years of production and development of aircraft brakes have led to new products and applications utilizing the technology and unique properties of carbon/carbon.

2.Advanced Composites - Aerospace - Radio Controlled Unmanned Aircrafts: Aerospace was the first widespread "commercial application" of Advanced Composites. From the early days when advanced composites were used for small "inconsequential" non-structural components in an aircraft - to today when entire fuselages and wings are constructed of advanced composite materials - the aerospace industry has come a long way. In the new Airbus A380 and the Boeing 787 Dreamliner - advanced composites account for 25% to 50% by weight - a scenario unthinkable even 5 years ago.

Manufacturing such critical composites require dedicated attention and immense skill. Each component is literally "hand-made" to client specifications. Eternus India has dedicated personnel attending to and owning the manufacturing process for such advanced composites.Aerospace composites are extremely critical - since many lives depend on a composite structure performing as it should in an aircraft. And thus, this industry is leading the effort of establishing robust quality systems like "material traceability" (where each and every raw material is tested before being used and a material trace can be carried out to the most primary level of the raw material for every composite component). 3.Thermal Protection System: The thermal protection system consists of various materials applied externally to the outer structural skin of the orbiter to maintain the skin within acceptable temperatures, primarily during the entry phase of the mission. The orbiter's outer structural skin is constructed primarily of aluminum and graphite epoxy. During entry, the TPS materials protect the orbiter outer skin from temperatures above 350 F. In addition, they are reusable for 100 missions with refurbishment and maintenance. These materials perform in temperature ranges from minus 250 F in the cold soak of space to entry temperatures that reach nearly 3,000 F. The TPS also sustains the forces induced by deflections of the orbiter airframe as it responds to the various external environments. Because the thermal protection system is installed on the outside of the orbiter skin, it establishes the aerodynamics over the vehicle in addition to acting as the heat sink. Reinforced carbon-carbon is used on the wing leading edges; the nose cap, including an area immediately aft of the nose cap on the lower surface (chine panel); and the immediate area around the forward orbiter/external tank structural attachment. RCC protects areas where temperatures exceed 2,300 F during entry. 4.SiC Conversion Coating for the space shuttle: Carbon composites have been used as structural components on many high technology,engineered materials, especially in aerospace applications.Exterior surfaces of these materials have to be protected from environmental effects.In the Space Shuttle application the effects of surface exposure are considerable the Shuttle enters the atmosphere at 18000 miles/hour.Surface protection against the highly oxidizing conditions has been provided by conversion of the carbon surface to SiC,a refractory material.The conversion is achieved by exposing the surface to silicon atoms at a high temperature, in an inert atmosphere.During engineering development of these coatings,materials were added to the silicon in order to evaluate whether they afforded improvement of the properties of the coating.The coating tested here included boron that was added because of the refractory properties of BC(boron carbide). 5.Applications of carbon/carbon composites: Carbon/carbon composites, developed about three decades ago to meet the needs of the space programme, are nowadays considered high performance engineering materials with potential application in high temperature industries. Accordingly, steady growth also prevails in the civil market segment. In terms of mass consumption, the main application of carbon/carbon composites are still in high performance braking systems. New innovations still owe to requirements from space industries. In general engineering sectors these are used in engine components, as refractory materials, as hot-pressed dies and heating elements, as high temperature fasteners, liners and protection tubes, as guides in glass industries etc. Some of the applications are shown in gure 9. Carbon/carbon composites have great potential in energy.

Figure. Carbon/carbon composite components. (a) carboncarbon brake discs, (b) turbine rotor, (c) resistance-heating elements, (d) protection tubes and grids.

6.As a weight reducing materials: Modern airliners use significant amounts of composites to achieve lighter weight. About ten percent of the structural weight of the Boeing 777, for instance, is composite material. Modern military aircraft, such as the F-22, use composites for at least a third of their structures, and some experts have predicted that future military aircraft will be more than two-thirds composite materials. But for now, military aircraft use substantially greater percentages of composite materials than commercial passenger aircraft primarily because of the different ways that commercial and military aircraft are maintained.

Conclusion: With carbon bre reinforcements in different forms and directions and thermosetting resins or thermoplastic pitches or hydrocarbon gases as matrix precursors, these composites can attain densities between 1.61.98 g/cm3.Reinforcing bres are more anisotropic in structure and properties than the carbon matrix. Accordingly, the properties of carboncarbon composites are dependent on bre volume content and bre orientation. Unlike polymer matrices, carbon matrices contribute signicantly to the ultimate properties of the composites, especially in case of pitch and CVD-derived carbon matrices. Carboncarbon composites are a family of materials with choice of variation in bre and matrix architecture, structure, microstructure, mechanical, thermal and physical properties etc. Hence these provide high performance materials for application in a number of sectors. References:

http://www.iitk.ac.in/infocell/iitk/newhtml/storyoftheweek42.htm http://www.hitco.com/HITCO%20Aero-Overview.htm http://www.aviation-database.com/Technical_Aviation_Articles/Aerospace-CompositeMaterials.html http://www.carbon-fiber-composite-materials.com/Eternus-India-Advanced-CompositeProducts/Advanced-Composites-Aerospace-Radio-Controlled-Unmanned-Aircrafts.html http://ceramics.org/ceramictechtoday/tag/space-shuttle-materials/ http://www.uscomposites.com/index.html