Komposites jiamen wound __A WORLD OF PRODUCTS FOR INDUSTRY __ Effective Performance—Efficiently + controlled erections! strength Industrial, aerospace and military products requiring high “high strengtn te weight rabo Performance propertos and extended elabiry n scveree low density (and low overall weight) Environments have achieved costetfective rests wh * controlled tlctical properties fiament wound technology Tlowdelecnciose . Filament wound components are designed to uilize the, papain or non-neuiaing capabilty synergistic characlersics ol einforcement resin ystems s remtandsrarareeeene and controled winding techniques. nengineerescomo7a-_& erPatearramradeckany ane machineabilty tons these varabes oer Mew coenliplonterrd The patermanc we on cer = st gece erat ce wh Fara » ee cog crater “ee ESPs nt sn str neg «tr mate oes and ct nb aun “ere tanec suntnare aig neta pea ees eee re, anareconones : : once es ‘altering the helical and windings of the glass rovings, * high pressure bottles Ce ese eEy. betaine end chmialnee not Seecsey econ a Lightwoight flament wound nose cone for he AIM Side ‘der missile. 2 ‘A hical wound pattern Left tonight: torque tube, rangible FAA Submarine radome housing for light tower and.a gun sivoud Tor mitary Sensiive radar equipment receNing tanks final napecton tt service on aUS. Navy vessel Tas Ce eensFILAMENT WOUND. TECHNOLOGY ENGINEERED MATERIAL VARIABLES: Filament Reinforcements, Glass filaments are the most frequently used reinforcements, athough aramid, ‘graphite, boron and specially com- Pounded materials are becoming more ‘common to the production floor as proven reinforcements in specialized applications Unlike metals, glass reintorcements, have no yield point. They exhibit per- fectly elastic behavior rom no-load 10 ‘upture and they do not creep under stress, See Table I for a comparison of properties of glass vs. stee!, Resin Systems Both epoxy and polyester thermosetting resins have achieved commercial suc- cess in filament wound products. Often, the special needs of each product can be met with several resin systems and fillers. Engineers will baiance these systems 10 achieve the most effective pertormance/cost ratio, ‘The most important functions of the resin systems are to: '* position the load bearing laments ‘distribute the load evenly among laments '* protect filaments from abrasion ‘control electrical and chemical resis- tance properties '* provide intertaminar shear strength PROCESS CONTROLLED VARIABLES ‘Mechanical Properties Reintorcement/resin ratios, winding teo- ‘sion and winding pattems establish ‘mechanical properties ofthe finishes product as summarized in Table I. Cit- ‘cumferential hoop windings and more longitudinal (helix) windings at pre- determined wind angles gre ditectional ‘strength as requted fr exch design. Figure 1, and Figure2. show the elative effect of wind angle on modulus o| elas- tay. High directonal stitiness, thigh modulus of elasticity) is achieved atwind angles approaching both zor0 andrninety degrees. Process/product efficiency is reflected in thin wall sections, Compared to 7075 15 Aluminum, a glass reinforced filament wound 6” I.D. tube with a 3000 psi max- imum rating, weighs half as much and thas a:38% thinner wall section. Forinter- ‘al pressure vessels this comparison yields a 214% impravementin efficiency based upon the ralioof pressure » vole lume per weight of metovia (ie. PV/ Wt). Comparisons of structural eficiency may be shown by relative losa carrying ability per unit weight af material. Table Willustratey the high strength, light- weight advantage of filament wound ‘composites. ‘Thase mechanical characteristics are based upon valves obtained in a 50- 300'F operating range. For higher tern- peratures the strongth is reduced, for low lemperatures, the sirengthis increased. The resin system isthe limiting factor at high temperatures since glass retains its strength up to 1000°F. Special resin ‘systema are available to allow operation ‘at temperatures in excess of 500°F. In reported cases, strengths at -424°F were 150% of strengths at 70°F. without bite failure, ‘¢ Machineabilty: Filament wound compo- ‘ents are machineable to close toler- ‘ances. Coolants and exhaust ventila- tion are required for dust control and to help minimize equipment wear. * Weather resistance: High molecular weight thermoset resins in filament wound components offer excellent re- sistance to ultraviolet radiation, tem- erature extresnes and moisture. Dis ‘coloration, erosion o fiber prom ‘Hence are minimal on “as wound ‘surfaces. UV stabilizer additives and ‘special coatings for machined surfaces help fo extend produc fe in severe ‘environments. ELECTRICAL PROPERTIES Both resin and glass are excelent in- sulators and are nonmagnetic. They wil ‘ot ntertere with radar oF radio tre= quency signals. Unde: special citcum- stances these characteristics may be ad Justed wih conductive faments, wound- {nreflective shielding. or surtace meta fizing, Basic electrical properties are shownin Table WV. CHEMICAL RESISTANCE PROPERTIES. With few exceptions, filament wound ‘materials are more resistant to chemical corrosion of weakening than stainless steel, mone! or titanium. Sample or Drototype testing is always recom- mended to verity compatibility a given environment. Resistance to a wide variety of chemical environments can be achieved by proper choc of es and reinforcoments. PHYSICAL PROPERTIES (Glass Reinforced), * Density. Gtass (% by wt.) | Density (l./in’) © 62 to 088 20 ore 0, 82 Typical 75-85, ove © Thermal 92 t0 220 BTU Conductivity he /in/i27°F (6.6 * 10"*107.6 10-* calfomiems"C/sec) * Thermal Coetficient of Lnear Expansion: 56 « 10~*in/in7 F(9 = 10°*10 108 » 40°" em/em/"C). '* Surface finish inside is governed by the finish quality ofthe mandrel and care dur- ingextraction, * Surtace finish outside ranges trom srregular as wound to very smooth ‘ground surlaces * Special surtaces are available to meet ‘needs forlow triction or special protection, '* Hardness: Barcol 40-75 10,000,000 3 axial Hoop, 2 8,000,000 3 6.000.000 4 3 4,000,000 3 2,000,000 3 é ° 2 « Cy Cd wind angieaegrees) tg.2 VARIATION OF EFFECTIVE MODULUS WITH WIND ANGLEDESIGN CONSIDERATIONS Deflection (sitness) may be increased (F decreased in filament winding by changing the winding pattern. Homo- geneous materials (non-fibrous) are only capable of changing this property by increasing or decreasing the cross section Frangitle Joints. C-K can offer a system (of controlled torce breakaway joints in which require controlled force breakage. Intertaminar shear stress. n good design practice, he reinforcement fila- ‘ments carry all staticand dynamicloading without transferring appreciable stress to the resin system, “Integral Winding” technique provides high shear strength Liners, coatings and inserts. Some ap- plications require properties that cannot be achieved with filament winding alone. {In these cases materials that wil perform ‘properly are added either inside or out- ‘ide as liners or coatings, Inserts are fre- ‘quently used to overcome fastening problems. Common shapes. Sections o evolution such as round, square, rectangular, oval. teardrop or any eonvex shape can readily be wound, Concave or intersect: ing surtaces are dficut and should be avoided for lament winding ‘Size. Finished products up to forty feet in length and forty-eight inches in diameter are within our present capabily Cost/pertormance. Tooting complexity {and ight tolerances add to the overall ‘cost of ary design. By combining mech- {nical functions or assembles ito a Single filament wound component, cost/ performance benefits can be achieved. Greater use of tlament winding prop ‘erties wil yield better pertormance at lower cost over other materials and pro- ‘cesses, Tablas V and Vi summarize propery ubizations and costs o typical filament wound products. PRODUCT CONSISTENCY Process integrity and part to part uniformity are assured by computer con- trolled winding equipment. a high capac ity protile sander, a wide range of cuting ‘and machining equipment, and most im- portant by skilled craftsmen who are Proud of their work, ‘Quality assurance and testing standards are an integral part of our ‘manufacturing procedures. Complete ‘documentation and government centiica- tion requirements are routine. WORKING WITH C-K (Our skilled engineers and field rep- ‘esentatives are available to discuss your ‘application. With their evaluation it may bbe possible to improve etficiency and Perlormance while reducing the cost of ‘your product through redesign in a filament wound camponent Table | Properties of High Strength Glass Filaments Vs. High Strength Stee! Filaments | ‘Yours Tensile ‘Speciic Tensile Grade Density Composition Modulus Strength ‘Strength tin.) or type ost) (es) (oe.fin’) (ten, ste/density) c Calcium Alumina 10.7 «108 450,000 ove 4,300,000 Borosilicate s Magnesia Alumina 124 no 650,000 090 7,220,000 Silicate Music Drawn Carton 290%10 ‘590,000 urt 289 200,000 Wire Steet 004” 500,000 iets Table Il Mechanical Properties of Filament Wound Products (Glass Reinforced) Floxural Strength Bearing Strength Density 0,000-78,000 psi 2.000-35.000 psi (068. 062 1 /in? Property ‘Typleal Values, Predominant Process Variables? Woacive of Eaatichy 73,000 000-6 000.000 psi Glass Type, Wind Patiorn (Tension) Tensile Strength: Helical Windings '50.000-150.000 ps1 8 Type. Gi Patiers Compressive Strength Helical Windings 40,000-80 000 psi sin Hatio, Resin Type, Wind Pattern ‘Shear Strength “intertaminar| 3,000-20.000 ps Resin Type, Wind Patern, Cross! 18,000.20 000 Giass/Resin Rato, Resi Type Modulus of Righty 1.600,000-2,000,000 psi Wind Pattern (Torsion) Wind Pattern, Glass/ Resin Ratio ass/ Resin Ratio (Resin Ratio. GiTable Ill Comparative Strength to Weight Ratios (Specific Strength) aon vests, | Teagan | eeetagee 7 (stint seen ton) ‘i658 Siength tn) Fa cg On oars ‘some s zm “a ow ssw wa ss carro on vse 0 ero roommate s8698 ove vo v0 | Table IV Electrical Properties Table V Product Value Improvement Analysis. ig | ep peo ronson | ie "pene" Teen FWRPT agit Meter 4.2.9.7.8 Weide Stee! ers Dielectric Constant (ASTM Test 0 150-647) Tanks ar ee oop as en Povo Fctast ton1806M "agin xr = arf st i haan aap er vu aston Rests AT 250 ae ae 150-100 sec, Chemical Pipe 3.4,7,6,0 OF Stainiess sect reg AS 00 a Tet lo ‘Step-by-step, perpendicular Mose 5.7, - Sto ie pred = sm [oceemem siren Loss Tan, (ASTM Test 0 150-647): ime Reap ae 2 Eatiate riences ‘Table VI Relative Costs moa ootzineateas, uanty Mande cont Pie iow oe tw bes Elected Mederse Lave Mecerate ‘ame Vs ecerte toh rat Nossa fcr ae oh ma ten C-K Composites of Canada. 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