Auto Racing Composites

Roush Racing takes us viewers on a tour through their composites shop in a short clip from Roush TV.

Using mostly carbon fiber and kevlar reinforcements, Roush Racing fabricates many different components for the racing industry using epoxy resin systems.  Ranging from the front noses for the NASCAR Car of Tomorrow car to drag racecar bodies and small ductwork, Roush Racing’s composites shop does all sorts of fabrication.

The race shop includes two different fabrication processes.  Wet layup vacuum bagging is used for some parts, while others are made using prepreg material that goes into an autoclave.

The video tour is well done, and includes everything from the Eastman material cutter to the fabrication process, bagging process, and trim.  We also get to see some of the finished parts after they are demolded and trimmed.

These parts are very expensive to manufacture, due to the high cost of materials and labor.  Tooling and equipment costs for this type of process are somewhat reasonable, with the exception of the autoclave and the automated cutting table.  Composites fabrication of this caliber is labor intensive, but can produce very unique parts that are lightweight and strong.

Carbon Fiber Yike Bike

People are coming up with a lot of great products made of carbon fiber composites.  The nature of these products makes the use of composites a requirement.

I found an interesting video of a very specialized carbon fiber bike.  Called the Yike Bike, it is basically an electric scooter that allows for urban transportation.  The bike folds into a small and portable unit that can be easily carried and stored.

The use of carbon fiber is necessary due to the requirements of light weight and high strength.  It is necessary for this scooter to support and transport people of various size and weight.  The bike also must be lightweight so that it can be easily carried aboard trains and into office and apartment buildings.

This unit is definitely a feat of engineering, and is available to the public in the Summer of 2010.  It is pricey, but fills a unique role for those that require urban transportation.

Non-Destructive Testing with Ultrasound

Composite materials can become damaged in many different ways.  There can also be flaws in the original manufacturing process.  Many times it is necessary to identify any damaged areas within the composites layers that cannot be detected with the eye.

Inspection of composites fiberglass and carbon fiber structures may be required for advanced critical applications of composites materials.  Identifying any potential problems with the composites structure is extremely important.

Of course problems can be identified through destructive testing-drilling holes, making cuts, etc.  It also may be necessary to do testing in a non-destructive manner, i.e. not cutting into the laminate that is being tested.

One method of accomplishing non-destructive testing of composites laminates is using ultrasound.  This Youtube video demonstrates the use of this method.

As you can see, the damage is found in this carbon fiber laminate.  This information is a flag that can be used to decide whether to make a repair or replace the structure.

Delamination within the fiberglass or carbon fiber part will result in a much weaker structure than the design intended.  Other areas of the composites part will be further strained by weaknesses in other areas and may also fail.

This ultrasonic test can help to identify otherwise invisible problems with either the original manufacturing process or damage during the life cycle of the composite part.

Cirrus Composite Airframes

I found a very interesting Youtube peek inside of the Cirrus airplane assembly factory in Minnesota.  While it would be cool to learn more about the actual composites fabrication of the individual parts, there is some great information about part bonding, inspection, and final assembly of the Cirrus aircraft.  They use fiberglass and carbon fiber reinforcements to create a very strong and durable fuselage, and it is great to see in action.

Personal jets made of composite materials offer many advantages and unique properties.  Design of complex shapes and anti corrosion of aluminum are two advantages.  Disadvantages include repeatability and upgrading/modification.

Composites that are properly designed and fabricated can be used in many applications where safety is a big concern.  Proper design and inspection during production can create an airplane that can be easily maintained and have a very long life.

Great factory tour courtesy of Aero-TV:

NASA Composite Crew Module

NASA, the space agency for the U.S. government, has investigated the use of advanced composites for use in future vehicle programs.  The Composite Crew Module (CCM) has been designed and built as a travel vehicle for astronauts in future space programs to travel.  Drawing parallels to the Apollo program, this module will be launched on a rocket and break away as a module.

This technology and material are undergoing testing and evaluation before it is officially accepted for the Orion program.  As a partnership between government agencies and public companies, this technology aims to reduce weight and improve performance of the manned vehicles.
From NASA’s website “Led by the NESC, the project team is a partnership between NASA and industry, including design, manufacturing, and tooling expertise. Partners are civil servants from nine NASA Centers – ARC, DFRC, GRC, GSFC, JSC, JPL, KSC, LaRC, and MSFC; the Air Force Research Laboratories; and contractors from Alcore, Alliant Techsystems, Bally Ribbon Mills, Collier Corporation, Genesis Engineering, Janicki Industries, Lockheed Martin, and Northrop Grumman. The CCM team operates in a virtual environment, electronically connecting participants across the country.”

This full-scale structure has strain gauges attached to monitor loads on the structure.  It was announced on January 25 that it has passed a battery of stress tests to prove viability.

The structure appears to be made with carbon fiber materials, maybe with some graphite reinforcement and an epoxy resin system.  Mention of aluminum honeycomb can be found in the online reading materials.  The main pieces are autoclaved, while bonding of the large sections (upper and lower shells) is accomplished outside of the autoclave.

Composites technology is being developed for future space exploration structures and vehicles, and this is good news for the composites industry!