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Composite Panels & Adhesives

Composite Panels & Adhesives. Composite Panels. Panels are fiberglass on both sides with a core in the middle consisting of either foam or a honeycomb structure. Core Options. Final Core Material. HT Diab 61 - Wing Skins Ability to lay up curves of Airfoils

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Composite Panels & Adhesives

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  1. Composite Panels& Adhesives

  2. Composite Panels • Panels are fiberglass on both sides with a core in the middle consisting of either foam or a honeycomb structure

  3. Core Options

  4. Final Core Material • HT Diab 61 - Wing Skins • Ability to lay up curves of Airfoils • Cheapest that met criteria of foams • Aramid Core - Spar, Aft Spar, Rib • Light Weight • Cheapest per Pound

  5. Adhesive Options • DP 420 • 3M, Two Part Epoxy • From 3M Epoxy Comparison

  6. Adhesive Options (Cont.) • PTM & W: • ES6292 Lightweight Tough Epoxy Adhesive • Two Part Epoxy • Designed for use in the structural assemblies involving composites • Already used by Cirrus Design Center

  7. Adhesive Testing • Objectives: • Test Max Adhesive Loads • Need to make sure adhesives aren’t effected by surfaces • Test surface preparation techniques

  8. Adhesive Testing (Cont.) • Materials Tested: • Adhesives: • PTM & W ES6292 • 3M DP 420 • Composites: • Aramid Core with Fiberglass Skin • HT Diab Foam Core with Tencate Fiberglass

  9. Adhesive Testing (Cont.) • Tensile Test: • Load Bonds in Tension • Measure Load at Fracture • Calculate Lbs/In. Bond Strength • Test Equipment: • Constant Strain Load Cell • Measures Load and displacement

  10. Adhesive Testing (Cont.)

  11. Adhesive Testing (Cont.) • Tensile Load Justification: • Jaws: • 2° freedom on both directions • Top & Bottom • All samples were applied within 1 degree of perpendicular • Therefore: Tension loads were perpendicular to bond

  12. Adhesive Testing (Cont.) • Surface Preparation: • All surfaces were lightly sanded to rough up surface • All surfaces were cleaned with to remove

  13. Adhesive Testing (Cont.) • Results: • Bond Strength per Inch of Bond (Lbs/In) • PTM & W ES6292= 81.7 ± 4.1 Lbs/In • 3M DP 420=87.1 ± 4.4 Lbs/In • Uncertainty Estimated at 5%

  14. Adhesive Testing (Cont.) • Conclusions: • Adhesives were comparable in Strength per Inch • Both Adhesives meet strength requirements for wing • PTM & W ES6292 Adhesive is better because of lower cost

  15. Adhesive Testing (Cont.) • Errors: • Improper preparation: • Issue: Samples broke at surface • Resolution: Better Surface Preparation • Sanding (possibly Sand Blasting) • Better Removal of oils from surface • Effect: • Bonds Broke Prematurely • With Better Preparation Bonds could hold more Weight

  16. Adhesive Testing (Cont.) • Test Equipment: • Issue: Jaws Slipping • Resolution: Better Transition from Material to Jaw • Adhere Aluminum Tab into Composite • External Clamp System with Aluminum Tab for Jaw • Allow Material to be secured by clamp and Jaw to attach to Aluminum Tab • Effect: • Load might be underestimated. • Result: Bond Strength could be higher than reported

  17. Adhesive Testing (Cont.) • Further Testing: • Shear Test Side View:

  18. Adhesive Testing (Cont.) • Shear Test Top View: (Load Pulling out from picture)

  19. Adhesive Testing (Cont.) • Shear Test:

  20. Epoxy Safety Precautions • Effects of Overexposure: • Eyes: Causes severe conjunctive irritation, Corneal injury and Iritis • Skin: May cause irritation, burns, ulceration, or skin sensitization • Inhalation: Vapors are irritating and cause tears, burning of nose and throat, coughing, wheezing nausea and vomiting

  21. Epoxy Safety Precautions (Cont) • Ingestion: Moderately toxic, may cause mouth and throat burns, abdominal pain, weakness, thirst and coma. • Chronic: Amine vapors may cause liver and kidney injury. Eye, skin or lung may develop or be irritated by Amine vapors. [From MSDS of ES6292B with Beads]

  22. Epoxy Handling Precautions • Respiratory: • Not required unless process is creating dust, mist or vapor. • Ventilation: • Breathing of vapor must be avoided. • Hand Protection: • Impervious gloves, neoprene or rubber, must be worn

  23. Epoxy Handling Precautions(Cont.) • Eye Protection: • Splash proof Goggles or safety glasses • Other: • Clean body covering clothing and shoes [From MSDS of ES6292B with Beads]

  24. Aramid Core Handling Requirements • Ventilation required when machining produces dust, mist or vapor • Light Hand Cotton gloves for General Protection [From Aramid Core MSDS]

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