SAE R-440-2015 Economics of Composites (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf

1、Economics of Composites Economics of Composites Economics of Composites The industry experts who authored this book explore the a ordability of composites ranging from raw material to end-of life disposal costs. The material characteristics, applications, and complex manufacturing to meet the demand

2、 for composites depend on many factors, and the panel of writers, from various industry segments (i.e., commercial and military aerospace, wind energy, automotive, and bicycle industries), address them with expert perspectives. Industry strives to provide customers with products that optimize econom

3、ic e ciencies. Manufacturing processes and development sustain product innovation and foster economic growth and the integration of automation and focus on productivity and achievement of quality improvements. The presentation by these authors captures this interaction and their in uences on the com

4、posite marketplace. Chapter subject material includes the economics of composite structure and speci cs of composite assembly. The spectrum of composite materials is detailed, and product and human health, along with safety and environmental impacts, are illustrated. George N. Bullen Carroll Grant A

5、lan Hiken Dan Day David Champa About the Authors George N. Bullen is an internationally recognized expert in inhabited and uninhabited aerial vehicles, space vehicle design and manufacture, laser weapon system design and manufacture, and lean processes and applications, as well as a consultant to in

6、dustry. He has been awarded 16 U.S. and international patents, which are the basis for all current automated systems for the assembly of airframes in the United States and Europe. Carroll Grant possesses aerospace/aircraft industry expertise in the eld of automated processes for aircraft composite s

7、tructures as well as metal aircraft structure. He is especially knowledgeable on automated ber placement (AFP) and automated tape layer (ATL) processes and is an independent contractor/consultant to the aerospace composites industry. Alan Hiken is a subject matter expert in composites manufacturing

8、with more than 30 years of experience in the aerospace and defense (A email: copyrightsae.org; phone: +1.724.772.4028; fax: +1.724.772.9765. Printed in the United States of America SAE Order Number R-440 http:/dx.doi.org/10.4271/r-440 Library of Congress Cataloging-in-Publication Data Bullen, George

9、 N., author.Economics of composites / by George N. Bullen, Carroll Grant, Dan Day, Alan Hiken, David Champa.pages cmIncludes bibliographical references.Summary: “The authors of this book explore the affordability of composites ranging from raw material to end-of life disposal costs. The material cha

10、racteristics, applications, and complex manufacturing to meet the demand for composites depend on many factors. Industry strives to provide customers with products that provide economic efficiencies. Manufacturing processes and development sustain product innovation and foster economic growth and th

11、e integration of automation and focus on productivity and achievement of quality improvements. This book cap- tures this interaction and their influences on the composite marketplace”-Provided by publisher.ISBN 978-0-7680-8121-31. Composite materials-Economic aspects. 2. Airplanes-Materials-Technolo

12、gical innovations- -Costs. 3. Composite materials in automobiles-Costs. 4. Composite materials industry. I. Grant, Carroll, author. II. Day, Dan, author. III. Hiken, Alan, author. IV . Champa, David, author. V . SAE International (Society), issuing body. VI. Title. TA418.9.C6B77 2015338.47620118-dc2

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14、l be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SAE International and its authors are supplying information, but are not attempting to render engineering or other professional services. If such services

15、 are required, the assistance of an appropriate professional should be sought. ISBN-Print 978-0-7680-8121-3 ISBN-PDF 978-0-7680-8232-6 ISBN-epub 978-0-7680-8234-0 ISBN-prc 978-0-7680-8233-3 To purchase bulk quantities, please contact: SAE Customer Service E-mail: CustomerServicesae.org Phone: +1.877

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17、440_Insides.indb 4 8/17/15 2:45 PMDedication George N. Bullen To Natalie (my wife), Brian, and Lisa (my son and daughter). ALSO To The composite applications and manufacturing engineers who have met and continue to meet the challenges of making parts from this highly fickle material. David Champa To

18、 my wife Lisa and sons Michael and Christopher. Dan Day Id like to thank my wife and family for their consistent support throughout my career and stressful times and my colleagues who have expanded my knowledge of composites and their application. Alan Hiken The chapter is dedicated to all those who

19、 helped to teach me, who helped to guide me, and who provided me with opportunities to make mistakes and learn from them throughout my career. R-440_Insides.indb 5 8/17/15 2:45 PMR-440_Insides.indb 6 8/17/15 2:45 PMvii Foreword xiii Preface .xv Acknowledgments .xix Chapter 1 Introduction 1 Carroll G

20、rant, Aerospace Composites Contractor /Consultant 1.1 Introduction .1 Chapter 2 Influencing the Economics of Composite Structure Assembly .7 Alan Hiken, Aerospace and Defense Industries 2.1 Introduction .7 2.2 Weight Savings 8 2.3 Part Count Reduction .10 2.4 Design for Manufacturing and Assembly .1

21、3 2.5 ExampleBoeing 787 .20 2.6 ExampleAirbus A350-XWB .22 2.7 ExampleMitsubishi MRJ 22 References 23 Chapter 3 The Impact of Composites on Assemblies: The Multivariate Random Variable . 25 George N Bullen FSME, CPIM 3.1 Introduction .25 3.2 Air Vehicle Case Study .25 3.2.1 Uncollected In-Process Co

22、sts .29 3.2.2 Improving Design 30 3.2.3 Calculating an Economic Value/Cost in Hours 31 3.2.4 MROIn Service .31 3.2.5 Tooling .33 3.2.6 Drilling and Drill Bits 34 3.2.7 Drilling in Composites 36 3.3 Offset and Countertrade 37 3.4 Summary: The Global Supply Chain and Its Impact on Variability at Assem

23、bly 38 References 40 Chapter 4 Integrated Structural Health Monitoring, Embedded Sensors, and CompositesManufacturing 41 George N. Bullen FSME, CPIM 4.1 Introduction .41 4.2 Manufacturing .44 Table of Contents R-440_Insides.indb 7 8/17/15 2:45 PMviii 4.2.1 Monitoring Raw Materials (Composite Materia

24、l Value Stream Enhancement) .45 4.2.2 RFID-Aerospace Economic Case Study 53 4.2.3 Impact Damage to Composite Parts .56 4.2.4 Composite Tooling Management 59 4.2.5 Embedded SensorsDesign/Manufacturing Considerations .60 4.3 Summary 60 References 61 Additional Reading .62 Chapter 5 Integrated Structur

25、al Health Monitoring, Embedded Sensors, and CompositesParts and Products 63 George N. Bullen, FSME, CPIM 5.1 Introduction .63 5.2 Embedded Sensors .64 5.2.1 Practical Applications Examples .66 5.2.2 Wind Turbine BladesCase Study .70 5.2.3 Innovative Human Application .73 5.2.4 Innovative Airplane Ap

26、plications .75 5.3 Summary 77 Keywords 80 References 80 Additional Reading .81 Chapter 6 Health, Safety, and Environment . 83 George N. Bullen, FSME, CPIM 6.1 Introduction .83 6.2 Health and Safety 86 6.2.1 Fabrication 88 6.2.2 Use .97 6.3 Summary 100 References 102 Additional Reading .103 Chapter 7

27、 Total Life Cycle Cost of Composites .105 George N. Bullen, FSME, CPIM 7.1 Introduction .105 7.2 Elements of TLCC of Composites.106 7.3 Economics of Composites Case Study: Commercial Aviation .108 7.4 Comparing Composites and Aluminum . 111 7.5 Micro Economics and the Cost of Composites .113 7.6 Mac

28、ro Economics Calculations and Case Study 117 7.7 Summary 120 References 122 Further Reading .123 R-440_Insides.indb 8 8/17/15 2:45 PMChapter 8 Enabling the Full Potential of Composites .125 George N. Bullen, FSME, CPIM 8.1 Introduction .125 8.2 Metal Graphite Composites.126 8.2.1 Copper Graphite Com

29、posites 126 8.2.2 Silver Graphite Composite Compounds 127 8.2.3 Aluminum Graphite Composites 128 8.2.4 Light Metal Graphite Composites .128 8.3 Fiber Reinforced Composites 128 8.3.1 CFRPPlastic with Special Properties .129 8.3.2 Carbon Fiber Reinforced Carbon (CFC) .130 8.3.3 Glass Fiber Reinforced

30、Plastics (GRP) 131 8.3.4 Ceramic Matrix Composites (CMC) .131 8.4 Coatings for Composites 132 8.4.1 Silicon Carbide (SiC) Coatings .132 8.4.2 Pyro-Carbon Layers 133 8.5 Silicon Carbide (SiC) .134 8.5.1 Silicon Carbide Sintered Without Pressure (SSiC) 135 8.5.2 Hot-Pressed Silicon Carbide (HPSiC)/Hot

31、 Isostatically Pressed SiC (HIPSiC) .135 8.5.3 Recrystallized Silicon Carbide (RSiC) .135 8.5.4 Liquid-Phase Sintered Silicon Carbide (LPSiC) 136 8.6 Mixed Ceramics 136 8.7 Tribology 136 8.7.1 Special Tribological Applications 138 8.8 Thermal Management 138 8.8.1 Devices for Passive Heat Dissipation

32、 .138 8.9 Medical, Measurement, and Analytical Engineering 139 8.10 Medical Engineering 139 8.10.1 Arthroscopic Pins.139 8.10.2 Dialysis Measuring Cells 140 8.10.3 Dental Root Pins 140 8.10.4 X-Ray Rotating Anodes.141 8.11 Analytical Engineering 141 8.11.1 Atomic Absorption Spectroscopy (AAS) 141 8.

33、11.2 Conductivity Measuring Cells .142 8.12 Graphene/Au Composites 142 8.12.1 Medical 143 8.12.2 Solar .144 8.12.3 Condoms .144 8.13 Summary 144 References 145 ix R-440_Insides.indb 9 8/17/15 2:45 PMChapter 9 Composite Assembly .149 Dan Day, Associate Technical Fellow 9.1 Introduction .149 9.2 Desig

34、n .150 9.2.1 Performance Optimization Versus Assembly Considerations 150 9.2.2 Distortion Reduction .150 9.2.3 Balanced Layups 150 9.2.4 Symmetrical Layups 151 9.2.5 Unitized Structure .151 9.2.6 Bondline Preparation 151 9.2.7 Peel Ply 151 9.2.8 Solvent Clean 151 9.2.9 Plasma Clean 151 9.2.10 Co-cur

35、e versus Co-bond .151 9.3 Interlaminar Tension 152 9.3.1 Pullup and Out-of-Plane Concerns .152 9.4 Hole Quality Producibility 153 9.5 Corrosion Prevention .153 9.5.1 Stopping the Electrolyte (Water) .153 9.5.2 Lightning Strike Protection .154 9.6 Fabrication .154 9.7 Thickness Control .154 9.8 Bagsi

36、de Accuracy 155 9.9 Radius Thinning 156 9.10 Shrinkage and Bow Waves 157 9.11 Tool Material Selection .157 9.12 Hole Generation 157 9.13 Process Development .158 9.13.1 One Up Assembly 158 9.13.2 Drill Dry or Wet .158 9.13.3 Drill Selection .158 9.13.4 Drill Types .159 9.14 Assembly Automation .159

37、9.14.1 Drivers for Automation 159 9.14.2 Hole Generation .159 9.14.3 Dust Collection: Health Hazard 159 9.14.4 Hole Quality .160 9.14.5 All Diamond Drills 160 9.15 Defects 160 9.16 Quality Control .160 9.17 Summary 161 Further Reading .161 x R-440_Insides.indb 10 8/17/15 2:45 PMChapter 10 Return on

38、Investment 163 David Champa, Manager, HATCON, LLC 10.1 Introduction .163 10.2 Return on Investment (Wall Street) 164 10.3 Current Trends and Challenges 165 10.4 The Return on Investment Process .167 10.4.1 Evaluation Planning 168 10.4.2 Develop Baseline Data 169 10.4.3 ROI Proposal 169 10.4.4 Data C

39、ollectionDuring Installation .169 10.4.5 Data CollectionAfter Installation 170 10.4.6 Data AnalysisThe Effects 170 10.4.7 Data AnalysisConvert Time to Money .170 10.4.8 Capture Cost of Solution 171 10.4.9 Calculating the Return on Investment 171 10.4.10 Identify Intangible Benefits 171 10.4.11 Devel

40、op Reports and Communicate Results .171 10.5 Sample Calculation (Case Study) .172 10.5.1 Probe Approach .172 10.5.2 Vision System Approach .172 10.6 Summary 172 Reference .174 Additional Reading .174 Chapter 11 SummaryFinal Thoughts . 177 George N. Bullen, FSME, CPIM 11.1 Introduction .177 11.2 Cons

41、tantly Emerging Challenges That Impact the Cost of Composites 181 11.3 Uncollected In-Process Costs 183 11.4 Design .183 11.5 MROIn Service 184 11.6 Drill Bits for Composites 186 11.7 Drilling in Composites .187 11.8 Process Sensitivity.188 11.9 Final Thoughts.190 References 191 Appendix: Key Terms

42、and Definitions .193 Index .205 About the Authors 215 xi R-440_Insides.indb 11 8/17/15 2:45 PMR-440_Insides.indb 12 8/17/15 2:45 PMxiii Foreword A book devoted to the economics of composites authored by industry experts! Readers of the Foreword should stop for a moment and consider both where this m

43、aterial came from and why it is important to them. This subject has a plethora of lessons learned that were published internally by corporations based on their experiences with composite products; however, due to the proprietary nature of this material, these lessons are not available to this audien

44、ce. People and technology are critical elements to sustain product innovation in industry and to foster economic growth. Publication of this book is timely, as industry is striving to provide their customers with products that provide economic efficiencies, particularly in the area of energy consump

45、tion. George (Nick) Bullen, utilizing his experience and desire for technical excellence, compiled a wealth of knowledge on the subject of composites. His technical expertise is vast and centers on advanced manufacturing processes and development. Nicks experience includes spearheading the Aerospace

46、 Automation Consortium (ACC), a group of manufacturers, suppliers, and integrators concerned about the competitiveness of the aerospace industry. My areas of expertise as a production engineer are assembly integration and automation, focusing on productivity and quality improvements. In that capacit

47、y, Ive received numerous awards and distinctions, including CA Team Excellence Award (CTEA) gold awards, the American Society for Quality (ASQ) International Competition gold and silver awards, and Spirit of Quality Awards. Our professional relationship began at a WESTEC conference that resulted in

48、a unique aerospace collaboration. Achievements from this industry collaboration included the National Science Foundation Advanced Technical Education (ATE) program and the ACC. It is apparent that Nick possesses a strong desire to share his technical expertise with the technical community in an effo

49、rt to improve process efficiency. He has created a waypoint publication to assist the engineering/technical professional in charting a course for economic success. Chapter subject material includes both the economics of composite structure and specifics of composite assembly. The spectrum of composite materials is detailed. Product and human health, safety, and environmental impacts are illustrated. NASA initiated the Environmentally Responsible Aviation (ERA) Project in part to identify new aerodynamic structures that reduce weight and improve fuel efficie