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METAL MATRIX COMPOSITE FILAMENT WINDING
Brian Gordon, Senior Program Manager E-mail: [email protected]
METAL MATRIX COMPOSITE FILAMENT WINDING
Brian Gordon, Senior Program Manager E-mail: [email protected]
2007 Insensitive Munitions and Energetic Materials Technology SymposiumCo
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OutlineOutlineTechnology Overview Metal Prepregs MMC Consolidation Methods
MMC Filament WindingRecent Results Hydrostatic Burst Testing Axial Tension and Torsion Testing Attachment Testing Impact Testing Pinned Closure Testing
MMC Design Tool DevelopmentConclusions and Future Work
Technology Overview Metal Prepregs MMC Consolidation Methods
MMC Filament WindingRecent Results Hydrostatic Burst Testing Axial Tension and Torsion Testing Attachment Testing Impact Testing Pinned Closure Testing
MMC Design Tool DevelopmentConclusions and Future Work
3
Metal Prepreg Tape and Pultruded Shapes
Metal Prepreg Tape and Pultruded Shapes
Tape Width 0.25 to 1.50Tape Thickness 0.007 to 0.020Tubing 0.25 OD, 0.015 wallAngle 0.375 per leg, 90
angle
Other sizes and shapes possible
Tape Width 0.25 to 1.50Tape Thickness 0.007 to 0.020Tubing 0.25 OD, 0.015 wallAngle 0.375 per leg, 90
angle
Other sizes and shapes possible
4
Metal Prepreg Tape PropertiesMetal Prepreg Tape Properties
Material = Al2 O3 fibers in pure AlTemperature = RTEnvironment = AirDirection = [0]
Standard Tape:Fiber volume of 50%Width of 0.5 inchThickness of 0.015 inch
Material = Al2 O3 fibers in pure AlTemperature = RTEnvironment = AirDirection = [0]
Standard Tape:Fiber volume of 50%Width of 0.5 inchThickness of 0.015 inch
Vf Density(lb/in3)
Width(in)
Thickness(in)
F1tu
(ksi)E1t
(Msi)1tu
(%)
Mean 0.50 0.119 0.377 0.0134 210 33 0.63
Tensile Sample #712
Modulus = 36.13MsiR2 = 0.9999
0
50
100
150
200
250
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
Strain (in/in)
Stre
ss (k
si)
5
MMC Consolidation MethodsMMC Consolidation Methods
PROCESSINGMETHODS
Vacuum FurnacingVacuum Bagging
Tape/Fiber Placement Hot Pressing
Filament Winding
Hand lay-upWeighted fixtureGood for small partsGood for attachments
Hand lay-upEvacuated fixtureLarger components
Hand lay-upControlled atmosphereThicker componentsHigher fiber volumeFlat and curved panels
Automated lay-upCut/add/feed headLarge complex componentsOut-of-autoclave
Automated lay-upHigher fiber volumeLarge simple componentsOut-of-autoclave
Adhesive BondingHand lay-upRoom temperature cureBag and autoclave
6
Metal Prepreg Filament WindingMetal Prepreg Filament Winding
Analogous to PMC wet winding Based on MetPreg metal prepreg technology Spools of fiber are put on creel Tension is built into each tow Fiber bundle is dipped into the liquid matrix (molten
aluminum) to impregnate Impregnated fiber bundle is laid onto the mandrel
Low-cost, flexible processing for MMCs
Analogous to PMC wet winding Based on MetPreg metal prepreg technology Spools of fiber are put on creel Tension is built into each tow Fiber bundle is dipped into the liquid matrix (molten
aluminum) to impregnate Impregnated fiber bundle is laid onto the mandrel
Low-cost, flexible processing for MMCs
7
MMC Filament Wound Components
MMC Filament Wound Components
8
Fiber and Matrix Typical PropertiesFiber and Matrix Typical PropertiesProperty Units Fiber Matrix
Chemical Composition wt. % >99 Al2 O3 99.99 Al
Melting Point CF
20003632
6601220
Filament Diameter min (10-4)10-124-5 -
Crystal Phase - Al2 O3 -
Density g/cm3
lb/in33.9
0.1412.7
0.098
Tensile Strength MPaksi3100450
40-506-7
Tensile Modulus GPaMsi38055
629
Elongation % 0.7-0.8 50-70
Thermal Expansion (100-1100C) ppm/Cppm/F8.04.4
2514
9
Axial Tension Test ResultsAxial Tension Test Results
Sample Number E22 (Msi) 22
(ksi) Strain @ Max Stress (%)
1 16.894 11.84 0.340
2 16.704 11.90 0.327
3 15.428 10.70 0.233
Average 16.34 11.48 0.300
Std. Dev. 0.80 0.67 0.058
Cv (%) 4.88 5.9 19.5
10
Tension Test Stress-Strain CurvesTension Test Stress-Strain Curves
nn
o
o
o
1
1
)(
+
=
11
Torsion Test ResultsTorsion Test Results
Sample Number G12 (Msi) 12
(ksi) Strain @ Max Stress (%)
1 4.494 11.59 4.396
2 7.890 11.30 4.329
3 4.026 11.44 4.361
Average 5.47 11.44 4.362
Std. Dev. 2.11 1.45 0.034
Cv (%) 38.55 1.3 0.8
12
0
2000
4000
6000
8000
10000
12000
14000
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Shear Strain (%)
Stre
ss (P
SI)
Sample 1 - TorsionSample 2 - TorsionSample 3 - Torsion
Torsion Test Stress-Strain CurvesTorsion Test Stress-Strain Curves
13
Uniaxial Hydroburst TestingUniaxial Hydroburst Testing
14StrengthFiber lTheoretica
StrengthFiber DeliveredEfficiencyn Translatio
StrengthFiber Delivered
Strength Lamina Delivered
=
=
=
ftVpr
tpr
80% Translation Efficiency
80% Translation Efficiency
Uniaxial Hydroburst Test ResultsUniaxial Hydroburst Test ResultsWall
Thickness(in)
Length(in)
InnerRadius
(in)
FiberVolumeFraction
BurstPressure
(psi)
DeliveredLaminaStrength
(psi)
DeliveredFiber
Strength(psi)
Hoop Only[89]4
0.051 6.000 2.000 0.33 2700 105,882 320,856
15
Biaxial Hydroburst TestingBiaxial Hydroburst Testing
16
0
10000
20000
30000
40000
50000
60000
70000
0.0000 0.0010 0.0020 0.0030 0.0040 0.0050
Strain (in/in)
Stre
ss (p
si)
Cylinder Stress-Strain Response [45/89/89/45] Biaxial Hydroburst
Cylinder Stress-Strain Response [45/89/89/45] Biaxial Hydroburst
Failure Driven by Hoop StressFailure Driven by Hoop Stress
10 Gage10 Gage
17
Process DevelopmentsProcess DevelopmentsLow-angle helical winding - 20Low-angle helical winding - 20
Integrally Wound Domes and SkirtsIntegrally Wound Domes and Skirts
18
Attachment TestAttachment Test
19
Attachment Test SummaryAttachment Test Summary
WallThickness
(in)
FiberVolumeFraction
BurstPressure
(psi)
DeliveredHoopStress(psi)
HoopFiberStress(psi)
Translation Efficiency
(%)
Recent Cylinder Tests
0.050 0.43 2812 111,843 263,174 66
MIG 0.051 0.42 2235 87,087 207,349 52
Pulse MIG 0.052 0.42 2030 78,839 189,989 48
20
Bolt Hole TestBolt Hole Test
CylinderID
BurstPressure
(psi)
Delivered HoopStress(psi)
Hoop FiberStress(psi)
Translation Efficiency
(%)
100505 1078 40,679 104,306 26
101005 1257 50,280 125,700 31
21
Impact TestImpact Test6-ply cylinders2-lb weight0.625-inch indenterDrop heights of 6 and 12 inchesHydroburst testing after impact
6-ply cylinders2-lb weight0.625-inch indenterDrop heights of 6 and 12 inchesHydroburst testing after impact
CylinderID
DropHeight
(in)
BurstPressure
(psi)
Delivered HoopStress(psi)
Hoop FiberStress(psi)
TranslationEfficiency
(%)
100405 6 1686 64,846 162,115 41
100605 12 1065 40,189 100,472 25
22
Pinned Closure TestPinned Closure Test
23
Pinned Closure Test SummaryPinned Closure Test Summary
Tests were to establish baseline propertiesDetailed stress analysis not yet completedAT 1000 psi internal pressure, the stress in the MMC near each hole would be over 56 ksiThis is comparable to a quasi-isotropic PMCLower helical angle would dramatically effect the results
Tests were to establish baseline propertiesDetailed stress analysis not yet completedAT 1000 psi internal pressure, the stress in the MMC near each hole would be over 56 ksiThis is comparable to a quasi-isotropic PMCLower helical angle would dramatically effect the results
0200400600800
10001200
10 15 20 25 30 35 40 45
Time (sec)
Pres
sure
(psi
)
24
MMC Design Tool DevelopmentMMC Design Tool DevelopmentDesign tool for modeling MMC behavior is being developed for predicting properties of cylindersFiber strength adjusted to match burst pressure from uniaxial hydroburst tests (first row of table)Model predictions show good agreement with biaxial experimental data when the failure mode is hoop fiber failure (rows two and four)Other failure modes, such as helical fiber or matrix failure, show slight discrepancy from experimental results (row three)Model validation and modification is on-going
Design tool for modeling MMC behavior is being developed for predicting properties of cylindersFiber strength adjusted to match burst pressure from uniaxial hydroburst tests (first row of table)Model predictions show good agreement with biaxial experimental data when the failure mode is hoop fiber failure (rows two and four)Other failure modes, such as helical fiber or matrix failure, show slight discrepancy from experimenta