Thick 3D Woven Composites as a Standard Material: Manufacturing, Properties and Applications

摘要

Carbon fiber composites that can be used in design like metals (a.k.a. "Black Aluminum"), have long been a subject of wishful thinking. Many designers/manufacturers would like to use carbon/epoxy composites, but do not have the manufacturing expertise nor the needed facilities (RTM, VARTM or other closed molding equipment; chemical storage; molds; ovens; etc.) This paper will present the concept of using 3D woven composite materials as "standard" engineering materials, ready for machining and application. Not having the well-documented weaknesses of traditional advanced laminates, thick (5-25 mm) 3D woven composites will not delaminate, and can be designed and machined in a fashion similar to metals. These materials are made from single-layer one-piece 3D woven fibrous preforms, and then consolidated into a composite by VARTM. Composites were made with 3D woven carbon preforms and two commonly used resins; one vinyl ester and one epoxy. Tensile, compression, SBS and flexure date are presented. Applications/markets include after market as well as OEM components in areas such as Performance Auto/Cycle, Performance Marine, Sports and Recreation Equipment, Industrial Machine Manufacturing and other custom CNC fabricators. Several specific example applications are discussed.