BASIC COMPOSITE REPAIRCOMPOSITE DIVISION, AIRCRAFT STRUCTURE REPAIR DEPARTMENTINSTITUT KEMAHIRAN BELIA NEGARA PEKAN
MUHAMAD FADZRIN BIN MOHAMEDMOHD SYAHMI BIN SHARIFMOHD FAIZAL BIN SHAHIDEKTc. NORAFIZAN BIN RUPADIANISAH BINTI ABD HAMIDSUHAMI BIN SIDEKCOMPOSITE DIVISION, AIRCRAFT STRUCTURE REPAIR DEPARTMENT
HAK CIPTAINSTITUT KEMAHIRAN BELIA NEGARA PEKANMINISTRY OF YOUTH AND SPORTSKm 55, Jalan Kuantan - SegamatPaloh Hinai26650 PEKANPAHANG DARUL MAKMURMALAYSIATel: +609-451 4888Faks (Fax): +609-451 4999Laman Web (Web): http://kemahiran.kbs.gov.my
PRAKATASetinggi-tinggi kesyukuran dipanjatkan ke hadrat Allah SWT kerana dengan izin-Nya,buku Basic Composite Repair ini berjaya diterbitkan. Naskhah ini dihasilkan sebagaipanduan serta rujukan utama bagi para pelajar yang mengikuti pengajian peringkatSijil dan Diploma di institusi latihan kemahiran di Malaysia. Penerbitan buku inidiharap dapat menjadi pemangkin serta rujukan kepada para tenaga pengajar dalammemperkasakan penulisan bahan ilmiah pada masa hadapan. Mewakili barisanpenulis, saya ingin merakamkan setinggi-tinggi penghargaan kepada semua pihakyang telah menyumbang tenaga dalam menyempurnakan naskhah ini. Semogaperkongsian ilmu ini memberi manfaat yang berpanjangan kepada para pelajar danjuga penggiat industri.Sekian, terima kasih.MUHAMAD FADZRIN BIN MOHAMED Ketua Editor
ISI KANDUNGANI. HAK CIPTAII. PRAKATAIII. ISI KANDUNGANChapter 1 - Technology of CompositeClassification of CompositePolymer Matrix CompositeApplication of Composite in IndustrialChapter 2 – FiberConstituents – FiberFiber formFiberglass in manufacturingFiber UsageChapter 3 – Matrix of ResinConstituents – Matrix & ResinBinding AgentMatrix Properties Resin Mixing
What is Composite?Composites are made of two or more distinct materials combined together to become stronger and better
Technology of Composite• Composites materials are fibrous reinforcements bonded together with a matrix materials and the constituents can be identified separately.• Natural fiber - Occur naturally in your bones, in wood, horns etc• Engineered fiber - synthetic fibers• Allow the stiffness and strength of the material to change with direction of loading
Technology of CompositeNaturel Composite Synthetic CompositeBonesWoodGranite
Classification of CompositesBased on MatrixBased on ReinforcementMetal Matrix Composites (MMC)Ceramic Matrix Composites (CMC)Polymer Matrix Composites (PMC)Thermoplastic ThermosetThermoplastic Thermoset Sandwich Composite Laminated CompositeFibre-Reinforced Composite Particulate Composite Structural Composite
Classification of Composites• Based on Matrix– Metal Matrix Composites (MMC)– Ceramic Matrix Composites (CMC)– Polymer Matrix Composites (PMC)• Based on Reinforcement– Particulate Composites– Fibrous Composites– Laminate Composites
Constituents Polymer Matrix Composites Fiber• High Strength• High Stiffness• Low Density• Carbon, Glass, Aramid, Etc.Resin Composite• Good Shear• Low density• Thermoset & Thermoplastic• Epoxy, Polyester, pp, Nylon, Ceramic, etc.• High Strength• High stffness• Good Shear Properties• Low Density• Anistropic+ =
Composite Application in Various IndustriesIndustry ApplicationCorrosion Storage tanks, Piping Systems, Ducting SystemOil Field Piping System, Drive & Shafts, Tubular StructurePaper & Pulp Paper Roller, Piping System, Ducting SystemInfrastructure Column Wrapping, Tubular support, Power Poles, Light StandardPressure Vessel Water Heaters, Tanks, CNG Tanks, Breathing Apparatus Aerospace Rocket Motor Case, Aircraft StructureMarine Mast, Boom Structure, Vessel StructureSports & RecreationGoft Shaft, Bicycle, Wind Surfing, Amusement Rides
Composite Industries Market
Composite Industries in MalaysiaRM 9.86 BillionMalaysia Turnover, the Second Highest in South East Asia Source : MIGHT630,000Volume (tonne)>70Total FabricatorComposites has been used in a wide range of applications in Malaysia and contributes to growth in a diverse range of industry value chains from utilities through to boat building, manufacturing and industrial applications, aerospace, automotive, construction, maritime, defence and oil and gas.
FIBER
Constituents - FiberComposite
Constituents - Fiber Constituents - Fiber
Fiber Form• Filiment (1D)• Fabric/Weave (2D)• Tape/ Unidirectional(1D)• Mat (Random)
Fiber FormTow BobbinFilaments – individual filaments 4 to 20 um
Fiberglass ManufacturingVideo: How Fiberglass Is Made
How to Choose Right Fiber• Weight of Fiber• Fiber Direction• Weave of Fiber• Type of Fiber
Fabric Usage
MATRIX or RESIN
Constituents - Matrix• Purpose- Support and bind fiber togetherOperating TemperatureToughness propertiesLoad TransferFire Smoke & Toxicity PropertiesKeep Part GeometryKeep Fiber Orientation/ Position Environment Resistance
Constituents - Resin• Known as resin/ matrix/ adhesives• Good Fiber to resin ratio – 60:40• Thermoplastics and thermosetting resin
Binding AgentThermoplasticShape changes when heat is appliedAmorphous , semicrystalline, PEEK etc.
Binding AgentThermosettingShape gains stability after cured although heat is appliedEpoxy, Polyester, Vinyl Ester, Phenolic, BMI etc.
Matrix PropertiesRefer to MSDS of each Resin before use
Matrix PropertiesRefer to MSDS of each Resin before use
Resin MixingVideo: How to Mix Resin
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