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PREVIOUS MEETINGS
September 18, 2008
Boston SAMPE Student
Recognition Dinner - UMass
Lowell Student Posters
and Awards
Location: The Brewery Exchange,
Lowell, MA
July 28,
2008
Boston SAMPE
Chapter Annual Meeting -
Location:
The Brewery Exchange Lowell, MA
----------------
THURSDAY, March 15, 2007
SPEAKER
Ray Erikson Boston Flight Sciences, Inc. 175 New Boston Street Woburn, MA
01801-6203 Tel 781-935-8100 Fax 781-935-8102 ray.erikson@bfsigma.com
Advances in Sensor Structures and Materials
Abstract
Optical sensors, antennas and radomes are major drivers for mechanical design
and advanced materials development in aerospace and defense. Rising optical
system acuities demand increasingly stable elements and metering structures.
Rising antenna frequencies demand increasingly accurate reflector surfaces,
while rising antenna powers require lower losses in radomes for greater gain and
lower heating. The proliferation of antennas on aircraft requires careful
integration with airframes, leading to such concepts as "smart skins." The
presentation this evening will provide an overview of these applications and
some of the interesting ways material systems engineers have addressed sensor
system challenges.
About the Speaker
Ray Erikson holds an M.Sc. in mechanical engineering from Northeastern
University, but began his aerospace career in 1971 as a mechanic, and later
pilot, with Pocono Airlines. Since then has made significant technical
contributions to the NASA Space Shuttle, Space Station, several other spacecraft
programs, and to several tactical aircraft programs for the U.S. Air Force. In
addition to designing composite structures, performing finite element analysis,
and leading advanced material development projects, he has also planned launch
operations at Kennedy Space Center and flight testing at Edwards AFB. Besides
being a member of SAMPE, Ray is also the newsletter editor and a director of the
New England section of the American Institute of Aeronautics and Astronautics,
as well as director of public policy for the Northeast U.S., and chairman of the
international AIAA technical committee on space logistics.
LOCATION: DoubleTree Riverfront Hotel, 50 Warren Street Lowell, MA 01852
Directions: www.lowell.doubletree.com
TIME: Opening 5:45 PM, ~ Dinner 6:30 PM, ~ Presentation 7:45 PM
COST: $20 SAMPE Members, $10 SAMPE Student Members, $20 non-members
For reservations, please register electronically at www.bostonsampe.org or call
David Evans at (978) 935-2989. Please leave your name, phone number, company
affiliation, and dinner selection Reservations are required no later than 3:00
PM on Tuesday, March 13, 2007
THURSDAY, February 15, 2007
SPEAKER
Mike Favaloro Automated Dynamics 407 Front Street, Schenectady, NY 12305 Tel
978-270-6011 http://www.automateddynamics.com email mrfavaloro@comcast.net
Recent Developments in Advanced Fiber Placement Technology
Abstract
The automated fiber placement (AFP) process is a highly precise automated method
used to position unidirectional prepreg in the fabrication of composite
structures. In the process, a robotic head is used to guide, heat, debulk,
and cut prepreg as it is laid up on a tool. The automated process
typically results in substantial labor reduction and reduced material scrap,
which often justifies the cost of the robotic equipment in a reasonable time
frame. The process is used with either thermoplastic or thermoset prepreg.
This paper describes the AFP process in detail, and provides information on
process limitations and design considerations. The manufacture of various
composites with the AFP process will be described.
About the Speaker
Michael R. Favaloro holds a B.S. in Plastics Engineering from the University of
Lowell. In the late 1970's, Mike worked on compound development of engineering
thermoplastics at GAF in Wayne, N.J. In 1980, he moved to Avco Systems, where he
worked on process development of 2D and 3D carbon/carbon composites, reinforced
teflon radomes, and composite flywheels. In 1996, with the merger of Textron
Specialty Materials into Textron Systems, Mike became Director of the combined
composite business lines of the two divisions, where he was responsible for the
P&L of boron and silicon carbide fiber and prepreg, metal- and ceramic- matrix
composites, and inorganic matrix composites. As Textron sold off its materials
business lines Mike began working with different companies in various capacities
including technical consulting and business development. Some of the
companies Mike has recently worked with include Albany Techniweave, ARC
Technologies, and Automated Dynamics. He has written numerous technical
papers, including a chapter on ablative materials for the Concise Encyclopedia
of Chemical Technology, J. Wiley, 1998. He is on the Board of Advisors for e-composites.com.
LOCATION:
DoubleTree Riverfront Hotel, 50 Warren Street Lowell, MA 01852
Thursday, November 16, 2006
SPEAKER
Richard B. Warnock Materials Engineering Raytheon Sudbury, MA 978-440-1229
Richard_B_Warnock@raytheon.com
High Temperature Composites for Hot Trailing Edge Panels on Military Aircraft
High temperature environments (>500F) have been challenging environments for
organic matrix composites. Historically PMR-15 has been the resin of choice for
these applications. However, it contains a methylenedianiline (MDA) curing agent
which leads to health and safety concerns during manufacturing. Other resin
systems have been developed to replace PMR-15. This paper will examine a case
study on the application of a (then) recently developed high temperature resin
to the hot trailing edge of a military aircraft
Dick Warnock is a Principal Engineer in Materials Engineering at Raytheon in
Sudbury. He spent 17 years working for the US Air Force, the last 14 years as
the Lead Materials Engineer for the USAF Advanced Composite Program Office. He
also spent 4 years as Chief of Composite Technology and Director of Operations
of Continuum Control Corporation. He joined Raytheon IDS in 2003. Dick earned a
BS in Chemical Engineering from Rensselaer Polytechnic Institute, and an MS in
Mechanical Engineering from the University of California at Davis.
LOCATION: Radisson Hotel, 10 Independence
Drive Rte. 110, Chelmsford, MA, (978) 256-0800, www.radisson.com/chelmsfordma
Boston SAMPE – Chapter
News November 16, 2006
THE BOSTON CHAPTER OF SAMPE invites you to
join our Nov 16, 2006 Dinner Meeting at Radisson Chelmsford. Dick Warnock from
Raytheon will give the presentation.
ATTENTION SPONSORS: If you would like to have your company profiled in the
monthly newsletter, please forward your advertisement to Michael Benante, at
Aeroindustryjobs, via e-mail mbenante@aeroindustryjobs.com
LOOKING FOR A JOB? Through our alliance with Aeroindustryjobs, you have access
to job openings with the industry’s leading organizations. The jobs range from
entry level to executive level, and are all either Materials or Aerospace
related. To review these and other positions on the Aeroindustryjobs website, go
to www.aeroindustryjobs.com, click Search Jobs, and select to search jobs “By
Company”:
Here is the current list of companies and organizations:
AAR, BCG, Chartright Air Inc., HR Textron, Saenger Associates, SAMPE Online
Career Fair, Smiths Aerospace - Grand Rapids, MI, ALKAN Shelter, LLC, Alliance
Solutions, Corporate Strategies and Development, DR Technologies, Inc., Drake
International, Easton Technical Products, Eaton Corporation, FedEx Express,
Morgan, a Stanley Company, Reinhold Industries, Inc., TECHEXPO Top Secret, Tempo
Agency, Two Roads Professional Resources, Xintek, Inc.
ARC TECHNOLOGIES PLANT TOUR WAS A SUCCESS
Boston SAMPE would like to thank Todd Durant, Dave Hess, Mike Favaloro and their
colleagues for the informative and enjoyable tour last month. We learned a lot
and the dinner was great! Our thanks again to ARC Technologies.
WELCOME TO OUR NEW SPONSOR, PLASAN USA, INC
Plasan USA is a spin off from Vermont Composites and will be making composite
structures for automotive and ballistic armor applications. At this time we are
supplying the fenders for GM's Corvette Z06 and will be adding new products over
the next year. POC is Dan Maneely; 802 445-1700 x2233; dan.maneely@plasanusa.com;
www.plasanusa.com
NEWS FROM THE UNIVERSITY OF MASSACHUSETTS, LOWELL
John Mooskian has replaced Mike Alabran as the new president of the UML SAMPE
Student Chapter. He is a student in the Department of Mechanical Engineering,
and works for Prof. Julie Chen of the Advanced Composite Materials and Textile
Research Lab on the electrospinning of polymer fibers.
ASM BOSTON has invited us to join them in a special tour of the Army Natick Labs
on December 7, 2006.
Further details will be announced in the next newsletter.
NEW CHAPTER MEMBERS: We welcome all new members to the Boston Chapter. We extend
an invitation to join us for one of our monthly meetings, meet the officers for
the Boston Chapter and see what our chapter has to offer.
HAVE SUGGESTIONS: Your suggestions and ideas are important. What needs improving
or changing? We are dedicated to continuously improving the Chapter. Tell us
what you like or dislike. If you or anyone you know would like to be a speaker
please contact an officer of the Boston Chapter.
Boston SAMPE MEETING
THURSDAY, October 19, 2006
TECHNICAL PRESENTATION AND FACILITY TOUR
ARC Technologies, Inc. 11 Chestnut St Amesbury, MA 01913 (978)388-2993 http://www.arc-tech.com/
Sponsored by Todd Durant - Director of Sales and Marketing
ARC Technologies is the leading supplier of
microwave absorbing materials for commercial and defense applications. While
providing a complete range of standard absorber products, ARC Technologies also
offers dielectric materials, composites, radomes, and radar absorbing structures
(RAS). ARC Technologies is ISO 9001 certified. Today, ARC's 100,000 square foot
manufacturing facility comprises four focus factories that are responsible for
each of ARC's major product lines.
* MAGRAM
* Dielectric Materials
* Composites
* Advanced Materials
ARC leverages the experience of strong
technical teams from each focus factory to design solutions to interference
problems. Engineering disciplines include: Microwave, Radar, EMI/EMC, Polymer
Science, Production Processes
Our experience and capabilities in the area of compression molded elastomers and
our in-house rubber milling operation make us the only fully integrated MAGRAM
manufacturer in the US. ARC's Syntactic Foam products, consisting of both
tailored dielectric and controlled loss versions, have gained widespread
acceptance for use in aircraft, space, and antenna applications. ARC has
recently expanded its product line to include high temperature dielectric
composite structures which will be discussed in the technical presentation.
The visit will begin with a technical presentation of ARC Technologies
capabilities and programs, followed by a tour of the facilities. The evening
will conclude with a buffet dinner in the ARC cafeteria.
October 14, 2004
SPEAKER:
Michael Buck, Phoenixx TPC, Inc. 250 Cape Hwy, Rt. 44, Taunton, MA, 02718, USA
Tel: +1-508-977-9501 s Fax: +1-508-977-9502 Email:
MBuck11@aol.com
Low Cost Manufacturing Methods for
Thermoplastic Composites
The presentation provides background
information on the thermoplastic composite materials market, advantages of
thermoplastic composites, material types, and processing methods for fabricating
continuous fiber reinforced thermoplastic composite parts & structures.
Several different thermoplastic composite processing methods, the types of parts
that have been manufactured using them, the relative advantages & disadvantages
of each process, as well as many of the companies who currently utilize them to
manufacture parts for end use customers will be covered.
Thermoplastic pultrusion, molding/laminating (batch, continuous), automated tape
laying/fiber placement, and thermoforming type methods will be covered. A
list of suppliers and processors, including contact information, of
thermoplastic composite materials and parts will be included.
Mike Buck has been involved in the advanced materials industry for twenty years,
primarily in the area of polymer based composites. Mike was initially
employed at Textron Specialty Materials where he worked in engineering, product
management, and finally as the Business Line Director for their
commercial/sporting goods activities.
After Textron, Mr. Buck was employed briefly at Quadrax Corporation where he
worked with thermoplastic matrix composites. In 1998, several colleagues &
he co-founded Phoenixx TPC to manufacture thermoplastic composite prepreg tapes.
Phoenixx initially licensed and in 2001 acquired the Phillips Petroleum
thermoplastic composite processing technology. Phoenixx TPC is a leading
supplier of continuous fiber reinforced thermoplastic prepreg tapes, simple
pultruded profiles (rods, ribbons, ovals, etc.) & specialty long fiber
thermoplastic (LFT) compounds. Phoenixx TPC utilizes carbon/graphite,
glass (E-Glass, S-2), & aramid (Kevlar, Twaron) fibers to reinforce a wide
variety of thermoplastic resin matrices, including PEEK, PPS, PEI/Ultem,
PA/Nylon, PFA, HDPE, PP, & PMMA, among others.
Mike holds BS & MS degrees in Mechanical Engineering from the University of
Massachusetts and an MBA from Babson College.
Thursday, September 23, 2004
JOINT ASM-Boston SAMPE DINNER MEETING
SPEAKER
Dr. William E. Frazier, FASM, Naval Air Systems Command in Patuxent River, Md
Naval Aviation Materials Technologies
Virtually every material selected and
engineered for Navy and Marine Corps aviation is driven by the unique maritime
operational requirements and harsh corrosive environment. Carrier based
aircraft experience six times the structural loads of land based aircraft.
Aircraft are designed for a landing sink rate of 27 feet/second and are catapult
launch acceleration of 150 mph in 2.1 seconds. This presentation provides
an overview of the Materials Division at the Naval Air Systems Command.
The materials presented emphasize emerging metals, ceramics, and non-destructive
inspection technologies. Also discussed is the development of an aerospace
materials technology portal: the Aerospace Materials Technology
Consortium.
William Frazier received his B.S., M.S., and
Ph.D. degrees in materials engineering from Drexel University in 1981, 1984, and
1987, respectively. He is a graduate of the Naval Aviation Executive Institute's
Senior Executive Management Development Program and the Defense Systems
Management College's Advanced Program Management Curriculum. He is a Level III
certified member of the DoD Acquisition Professional Community and holds a Top
Security Clearance.
Dr. Frazier has 22 years of experience in naval aviation materials technology.
As the head of the Metals, Ceramics, and Nondestructive Evaluation Competency at
the Naval Air Systems Command in Patuxent River, Md., Frazier is the NAVAIR
authority responsible for safety-of-flight issues involving metals, ceramics,
and NDE. He is a recognized expert in materials selection and qualification,
failure analysis, light alloy development, intelligent processing of materials
and manufacturing technology. In June 1999, he received a Certificate of
Excellence from the assistant secretary of the Navy for outstanding
contributions as a member of the Manufacturing Technology Reorganization Team.
Dr. Frazier has authored more than 87 technical publications, edited six
books and holds two U.S. Patents. He is an ASM Fellow and a NAVAIR Fellow, and
serves as a peer reviewer for ASM's Journal of Materials Engineering and
Performance and SAMPE's Journal of Advanced Materials
Thursday, July 29, 2004
Annual Meeting – Radisson Hotel Chelmsford
Election of Board Officers, Boston Chapter
Meeting at 5:30 PM DINNER at7:30 PM
at Radisson Hotel Chelmsford Independence Bar and Grill 10 Independence Dr
Chelmsford, MA
www.radisson.com/chelmsfordma
THURSDAY, MARCH 18, 2004
Specialty Materials, Inc. FACILITY TOUR – 6 to 7 PM
1449 Middlesex Street Lowell, MA 01851
978-322-1972 www.specmaterials.com
Monte Treasure - President
Rich Caruso - Director, Marketing & Product Applications
Tom Foltz - Manager, Marketing & Sales
DINNER to follow tour – 7:30 PM
The Brewery Exchange 201 Cabot Street Lowell, MA 01854 978-937-2670
Specialty Material, Inc. is the manufacturer
of Boron monofilament and prepreg, as well as, SCS silicon carbide monofilament.
Boron monofilament is a very unique fiber in that it has extremely high
compression strength. Typical composite compression strength for boron
epoxy composites is in the range of 400 KSI. In addition, it provides high
composite tensile strength (220 KSI) and high composite tensile modulus (28 MSI).
Other attractive features of boron fiber are positive coefficient of thermal
expansion (CTE) for space applications, lack of need for coupling agents in
making strong and tough composites, and absence of galvanic corrosion with
aluminum. Specialty Materials’ SCS SiC fibers have outstanding high
temperature mechanical properties for increasing the strength, stiffness, and
use temperature of titanium matrix composites as well as, providing toughness to
ceramic matrix composites. In addition, it is used commercially to
increase the efficiency of the manufacture of solar cells used in photovoltaic
modules.
The Boston SAMPE visit to Specialty Materials’ facilities will begin with a
brief presentation of Specialty Material products and production history.
This will be followed by a tour of the boron and silicon carbide fiber
facilities and the boron prepreg production lines. The evening will
conclude at the Brewery Exchange in Lowell for dinner
January 22, 2004
SPEAKER
John Dignam , Vice President Mentis Sciences, Inc. 150 Dow Street Manchester, NH
03101
Phone: 603-624-9197 / FAX: 603-624-9254
www.mentissciences.com
High Temperature Composite Radome Development
Abstract
Although conventional organic composites have proven extremely reliable for many
years, they are not suitable for hypersonic hit-to-kill radomes. For these
applications, typically ceramic materials such as silicon, silicon nitride,
Pyroceram, and IRBAS are used to satisfy requirements. These ceramic
solutions are susceptible to thermal shock, thermal loading, inherently low
fracture toughness, and high acquisition cost. Although these
characteristics exist, there has not been an accepted composite solution to
replace these materials.
Mentis Sciences has developed a high temperature inorganic laminate suitable for
extreme environments. Composites based on inorganic polymers and quartz fibers
have been evaluated over the past 10 years. Precise placement of quartz
fibers improves both structural and electrical performance, and the similarities
in dielectric properties of the reinforcement and matrix result in efficient
signal transmission.
Critical factors for hit-to-kill interceptor performance are radar seeker
accuracy and missile weight/agility. Recent advances in fibers, resins, and
composite fabrication techniques allow the planning and initiation of programs
to develop advanced RF seeker protection. Mentis’ goal was to determine
the velocity-altitude driven, mechanical property limits for a thin-wall,
erosion resistant, high temperature composite radome. The
velocity-altitude profile where ablation and/or erosion caused sufficient radome
thickness reduction to occur was determined. This allowed a means for
in-flight structural thickness calibration. The overall rain erosion goal
of the program was a thin-wall, erosion resistant, radome capable of operating
successfully in moderate to heavy rain conditions.
The information contained within this presentation summarizes the nature and
scope of these efforts: the research and development of a low cost, inorganic,
polymeric radome material, suitable to provide (RF) electrical operations and
seeker thermal/structural protection for X, and Ka band missile systems
About the Author
Mr. Dignam is a Mechanical Engineer with 17+ years experience in research,
design, quality control, new product/process development, systems integration,
and project management disciplines. He is currently involved in the design
of advanced polymer matrix composite radomes as well as, PMC composite
structures, ballistic resistant textiles and laminates. He is responsible
for operations, sales, and program management at Mentis. Prior to joining
Mentis, he worked as a project engineer/manager for the Limbach Company, a
HVAC/process piping design firm. Additionally, he worked for 10+ years as a
manufacturing and operations manager in the food processing industry. He
has authored several detailed technical proposals and reports. He received his
BS in Mechanical Engineering and MBA from UMASS Lowell and is presently a
Doctoral candidate in Mechanical Engineering at the University
Thursday, JANUARY 22, 2004
SPEAKER
Dr. James A. Mondo President and CEO Automated Dynamics 407 Front Street
Schenectady, NY 12305 USA ph: 518-377-6471 ext 240, fax: 518-377-5628
www.automateddynamics.com
Right-Sized Equipment for Automated Fiber
Placement and Tape Laying
Abstract
One size doesn’t fit all when it comes to the use of automated fiber placement
and tape-laying equipment to fabricate advanced composite structures.
Right-sized fiber placement and tape laying equipment is built to a size,
complexity and budget right for the application and to meet the need of
aerospace primes and their suppliers to lower cost and increase productivity.
Large fiber placement and tape-laying
equipment have revolutionized the fabrication of large composite structures,
increasing quality and lowering material and labor costs at major aerospace
primes and a few of their very large suppliers. These machines have outstanding
versatility and size, and a price to match. Although well suited for large
parts, their use for small to medium sized parts or even large flat laminates is
difficult to justify at a multi-million dollar price. Right-sized equipment is
designed to make parts in production with capabilities and price tailored to fit
the fabricator’s application and budget.
After a discussion of the savings offered by
automated fiber placement and tape-laying, several present and future
applications of right-sized fiber placement and tape-laying equipment will be
discussed. The criteria for specifying right-sized equipment will be reviewed.
About the Author
James A. Mondo, Ph.D, is President and CEO of Automated Dynamics. After
receiving a Ph.D. in Physical Organic Chemistry from Yale University, he joined
the Pioneering Research Laboratory in the Fibers Department at the DuPont
Company in Wilmington, DE, where he carried out new polymer syntheses and new
product development. He moved into the newly formed Composite Division where he
was a program manager in the aerospace group. He moved to the Composite Division
at Phillips Petroleum in Bartlesville, OK, where he worked as the worldwide
marketing manager overseeing thermoplastic composite product development,
customer material qualifications and sales. He subsequently joined Quadrax
Corporation, a thermoplastic composite pre-preg material supplier, as general
manager. He later moved to Automated Dynamics as the business development
manager and became president in 1996. Automated Dynamics is a supplier of
thermoplastic and thermoset fiber placement and tape laying equipment and a
fabricator of thermoplastic composite parts for aerospace, industrial and
oilfield applications. Automated Dynamics currently operates five fiber
placement workcells at its facility in Schenectady, NY.
Boston SAMPE DINNER MEETING THURSDAY, NOVEMBER 20, 2003
SPEAKER
Mr. Charlie Hildebrand , Northeast Regional Sales Manager, NETZSCH Instruments,
Inc. 37 North Avenue, Burlington, MA 01803 USA
ph: 781-272-5353 x113, fax: 781-272-5225
c.hildebrand@nib.netzsch.us
Thermal Analysis for Composite Materials
Abstract
An overview of the different thermal analysis methods for characterizing
aerospace composite materials such as DSC, TGA, DEA, etc. will be presented. The
capabilities and limitations of these different thermal analysis methods, as
well as advanced analysis techniques such as simultaneous DSC/TGA with evolved
gas analysis by FTIR and mass spectrometry will be explored. Additionally, the
advantages of reduced pressure TG/FTIR for polymer analysis will be discussed.
About the Author
Charlie Hildebrand has over 20 years experience working with aerospace
components and materials. He has worked as a technical sales manager for NETZSCH
Instruments, Inc., and its predecessor, Holometrix Micromet for the past five
years. NETZSCH manufactures high performance thermal analysis and thermophysical
properties measuring instruments. Prior to his current employment, Charlie
worked as an engineer at Pratt & Whitney and GE Aircraft Engines, and as a
technical sales engineer working with aerospace materials and components. He has
a Bachelors degree in Mechanical Engineering from the University of
Massachusetts at Amherst.
OCTOBER 16, 2003
JOINT ASM-Boston SAMPE DINNER MEETING
SPEAKER
Joseph M. Wells, ScD JMW Associates 102 Pine Hill Blvd, Mashpee, NM 02649 (508)
477-5764, (Cell) (774) 836-0904
jmwconsultl@netscape.net, jwells@alum.mit.edu,
JMW_Associates@comcast.com
Summary of Damage Visualization & Characterization In TiC & TiB2 Ceramics and
Monolithic Ti-6AI-4V Alloy Armor Materials With X-ray Computed Tomography
Abstract
The detection, location and characterization of various defects within an opaque
solid volume are of considerable engineering and quality assurance interest in
many technological applications. However, destructive sectioning and polishing
are expensive, time consuming and irreversible processes which precludes the
further utilization of the subject object. Modem X-ray computed tomography, XCT,
techniques provide a unique nondestructive approach which creates a powerful 3D
volumetric digital interrogation of substantial size engineering objects.
Defects with significant density or x-ray absorption coefficients differences
are discriminated, isolated and analyzed in situ apart from the surrounding
matrix material. Various image analysis, reconstruction and visualization
techniques are employed and discussed for both TiB2 and TiC armor ceramics and a
Ti- 6AI-4V alloy target material from recent ballistic damage studies. A wide
spectrum of image analysis and 3D voxel visualization and analysis capabilities
will be discussed. Some items of particular interest to be discussed include the
discovery of spiral orbital cracking in the Ti-64 material and the sustainment
of 100% dwell or "interface defeat" despite the existence of an extensive
network of meso-scale cracking beneath the impact point in the TiC armor ceramic
sample.
About the Author
Dr. Joseph M. Wells received both his BS and MS Degree in Mechanical Engineering
from Northeastern University in Boston, MA in 1963 and 1965, respectively.
Subsequently, Dr. Wells earned his Sc.D. at MIT. Dr. Wells has worked as a
metallurgist and welding engineer with the Corps of Engineers, the U.S. Army
Materials and Mechanics Research Center (AMMRC) (Watertown, MA) as Chief of the
Army Corrosion Center of Excellence and served as Deputy to the Army Principal
in the DOD Project Reliance for the Technical Panel for Advanced Materials (TPAM).
He served as Deputy Installation Engineer at Tan Son Nhut in the Republic of
Vietnam, and held numerous management positions at Westinghouse Research &
Development Center.
Dr. Wells was involved in the development of improved armor ceramic and metallic
materials. He initiated the development of advanced x-ray computed tomography
techniques for the in-situ damage assessment of ballistic targets. He has edited
two published conference proceedings for TMS and has over 50 published technical
papers and reports.
Dr. Wells retired from ARL in September 2002 and is the principal technical
consultant of JMW Associates. His current consulting clients include DSTO of the
Australian Department of Defense, Lawrence Livermore National Laboratory,
Cornell University, and the US Air Force Research Laboratory. He is a Life
Member of ASM International.
THURSDAY, SEPTEMBER 25,
2003
SPEAKER -
Mr. Aram Mekjian Mektech Composites Inc.
40 Strawberry Hill Road , Hillsdale, NJ 07642 Tel: 201-666-4880
Fire Resistant Phenolic Composites
Abstract
Composites replace metal, wood and concrete in many applications because they
offer weight reduction, easier fabrication, corrosion resistance and lower
maintenance costs. They are increasingly used in Mass Transit, Aircraft,
Marine, Offshore Platforms, Construction and Mining. One drawback with
composites is that in a fire, they will burn, with most conventional matrices
such as unsaturated polyester, vinyl ester and epoxy emitting high levels of
heat, smoke and toxic fumes. Phenolics, which are fire retardant without
the use of fillers or additives, have excellent Fire/Smoke/Smoke Toxicity (FST)
properties. Phenolics are traditionally used in the form of prepregs,
which are expensive and difficult to use, or molding compounds, which are geared
for use in high volume applications. Recently developed phenolic resoles
which can be processed via Hand Lay-up, Spray-up, RTM, Vacuum Infusion, Filament
Winding, Pultrusion and Compression Molding will be reviewed as a means of
achieving excellent FST properties at low cost.
About the Author
Aram Mekjian is President of Mektech Composites Inc. He is the exclusive
Distributor of Cellobond Phenolic Resins (now owned by Borden Chemical Inc)
which he introduced to the US market in 1990 as Business Manager for BP
Chemicals. Prior to that, Aram was the Technical Director and Product Manager
for Aristech Polyesters for 13 years. He received a BS in Chemistry from
Valdosta State College, a MS in Chemistry and MBA in Marketing from Fairleigh
Dickinson University.
March 27, 2003
FACILITY TOUR
Composite Engineering, Van Dusen Racing Boats - Division of Composite
Engineering, Inc.
277 Baker Avenue, Concord, MA 01742 E-Mail: vandusen@tiac.net
Phone 978-371-3132 Fax 978-369-3162
http://www.vandusenracingboats.com/index
Composite Engineering of Concord is a
developer/manufacturer of lightweight racing hulls worldwide. Composite
Engineering rowing shells have been the standard of the "industry" for two
decades. Composite Engineering kayaks are used by US Olympic teams. Many other
products have been successfully developed by this enterprising composite
manufacturer. Composite Engineering specializes in knitted fiber sailboat masts,
spars and beams with low resin content utilizing low mass machine tool fixtures.
A unique feature of this innovative company is a cantilevered autoclave which
extends 20 meters horizontally from the Baker Avenue manufacturing site.
February 20, 2003
POLYMERS FROM RENEWABLE RESOURCES
Speaker:
Dr. Robert Whitehouse Metabolix, Inc. 303 Third Street Cambridge, MA 02142 Ph
617 492 0505 www.metabolix.com
Abstract
Metabolix, through the manipulation of microorganisms, has developed a pathway
for the economic production of polyhydroxyalkanoate polymers or “biopolymers”.
The initial commercialization route is through fermentation, similar to brewing
beer, but the yield is a polymer, not alcohol. In the longer term, Metabolix is
working to produce biopolymers directly in non-food crops, thus making them
competitive with commodity thermoplastic resins such as polyethylene and
polystryrene. This technology offers a sustainable approach to thermoplastic
polymers and reduces dependence on oil supplies.
Metabolix’s core technology is the development of high-performance, sustainable
polymers which are stable to water but will biodegrade in marine, fresh water,
composting and soil environments. The company is developing
polyhydroxyalkoanates (PHAs) from metabolically-engineered organisms through
fermentation and has just been awarded a US$7.4 million project to develop PHAs
directly in switchgrass by the US Department of Energy.
The presentation will discuss the polymer design space, properties and potential
applications.
About the Author
Robert S. Whitehouse, Ph.D., is Director of Applications Development for
Metabolix, Inc., Cambridge, MA. Dr. Whitehouse has a strong technical background
in surface chemistry and structure/property relationships with over 30 years of
experience in industry. Before joining Metabolix, Inc., he was senior member of
the Technical Staff and Director of the Industrial Rubber Products Group at
Cabot Corporation. He served as Group Leader in polymer additives at ICI and as
Forward Technology Group Manager at Evode, Ltd. A graduate of the Royal Society
of Chemistry, Wolverhampton Polytechnic, UK, his academic credentials also
include a Ph.D. He is a Chartered Chemist, as well as visiting Research Fellow
at Manchester Metropolitan University, UK where he has directed over 10 Masters
and Doctoral candidate projects. The recipient of numerous awards he is an
invited lecturer at prestigious conferences worldwide and author of a many
articles.
Dr. Whitehouse holds over 30 patents, including one invention for a new
technology platform for the controlled growth of polymer from particulate
surfaces. He also has extensive experience in consulting, management, corporate
restructuring, and mentoring and brings these skills to Metabolix, Inc. where he
is a valued member of the Operating Team. Other memberships include the Royal
Society of Chemistry, American Chemical Society, Fellow of the Royal
Microscopical Society, Society of Plastics Engineers. He also served as Past
Chairman of the Thermal Methods Group of the Royal Society of Chemistry and is
on the Board of the Massachusetts State Science Fair.
December 19, 2002
Overview of the Institute for Soldier
Nanotechnologies at MIT
Speaker:
Professor Edwin L. Thomas Director, Institute for Soldier Nanotechnologies
Morris Cohen Professor of Materials Science and Engineering
Abstract
The Institute for Soldier Nanotechnologies (ISN) at MIT is a new innovative
program, sponsored by the Army, with participation from industrial partners:
Raytheon, DuPont, and the Partners Healthcare System through the Center for
Integration of Medicine and Innovative technology (CIMIT). ISN research is aimed
at improving the survivability of individual soldiers through dramatic advances
in synthesis and processing of nanomaterials. Seven multidisciplinary research
teams, comprising approximately 35 faculty members, are supporting projects in
three key thrust areas: Protection, Performance Enhancement, and Injury
Intervention and Cure. This talk will focus on the work in nanotechnology
covering Energy Absorbing Materials, Mechanically Active Materials and Devices,
and Sensors and Chemical and Biological Protection. Both military and industrial
applications are expected to result from the research being conducted in this
program.
About the Author
Edwin L. Thomas is Director of the Institute for Soldier Nanotechnologies and
co-leader of the ISN's Team on Energy Absorbing Materials. He is also the Morris
Cohen Professor of Materials Science and Engineering. He received a BS in
mechanical engineering and engineering science from the University of
Massachusetts in 1969 and a Ph.D. in materials science from Cornell University
in 1974. Dr. Thomas served as associate head of the Department of Materials
Science and Engineering from 1995 to 1996, and from 1989 to 1995 he served as
the director of the Program in Polymer Science and Technology at MIT. He came to
MIT from the University of Massachusetts, where he founded and served as
co-director of the Institute for Interface Science from 1986 to 1989 and was
head of the Department of Polymer Science and Engineering from 1985 to 1988.
Some of Dr. Thomas's research interests include the morphology of block
copolymers; application of electron microscopy to disordered materials; and
optical properties of block copolymers and liquid crystalline polymers. His
honors and awards include the Special Creativity Award of the National Science
Foundation (1996 and 1988), the 1991 High Polymer Physics Prize of the American
Physical Society, and the American Chemical Society Creative Polymer Chemist
Award in 1985, and Fellow of APS in 1986.
November 21, 2002
Speaker:
Mr. Daniel Kass , GE Panametrics 221 Crescent
Street Waltham, MA 02453 www.panametrics.com
Ultrasonic Inspection of Composite Structures
Abstract
Ultrasonic systems are addressing the evolving needs for inspection of
manufactured composites. More critical structural aerospace components have ever
increasing complexity of shape and materials. Increased inspection reliability
has been realized through advancements in contour following and development of
specialized transducers for pulse-echo and through transmission ultrasonic
imaging.
An effective technique for complex contour following is to position the
transducers with multiple axis manipulators. Production inspection with large
robotic gantry systems with ten or more axes is common. The degree of accuracy
needed is application dependent. Pulse-echo imaging typically requires greater
precision than through-transmission scanning. Higher frequencies and more
precise gating increases the demand for precision contour following. Techniques
are emphasized that meet the increased precision needed with higher frequency
pulse-echo imaging. Developments are discussed. Actual production component
scans display the ultrasound data from difficult contours.
Research and development efforts on lower frequency, higher penetration
ultrasonic transducers, coupling methods, and instrumentation are also
discussed. These methods employ dry coupled 250 kHz roller probe composite
transducers and air-coupled transducers of 100 kHz and 250 kHz.
About the Author
Dan Kass has over 14 years of experience in the non-destructive testing field.
Mr. Kass has been employed with Panametrics during this time period as a
customer service engineer and sales engineer for general purpose and online
instrumentation. He is currently Manager of Automated Systems and
Instrumentation Sales and has co-authored papers on a variety of ultrasonic
techniques.
October 17, 2002 Dinner
Meeting
Speaker:
Garrett C. Sharpless, President, Fiber Innovations 24 Walpole Park South
Walpole MA 02081 Phone: (508) 660-2622 FAX: (508) 660-6662
gary.sharpless@fiberinnovations.com
Joint Air-to-Surface Standoff Missile (JASSM)
Composite Body
Rapid Response Process Improvement (R 2PI)
Program "Success Story"
September 19, 2002
PROCESSING WITH CYCLIC PBT TO PRODUCE THERMOPLASTIC COMPOSITES
Steven J. Winckler, Cyclics Corporation 2135 Technology Drive, Schenectady, NY
12308
email steve.winckler@cyclics.com
During the 1980’s and 90’s General Electric
developed low viscosity, cyclic thermoplastic materials based on the common
thermoplastics polybutlyene terephthalate (PBT), polycarbonate (PC), and others.
These low molecular weight cyclic oligomers have very low melt viscosities (some
as low as 17 cps), can be easily combined with fiber reinforcement, and
then rapidly polymerized “in-situ” using a variety of catalysts. They produce
engineering thermoplastics but process like thermosetting resins, making
thermoplastic composites a large scale reality. Cyclics Corporation
purchased the technology in 1999 and is commercializing it in the
composites industry with many possible fabrication methods and applications.
Fabrication methods include; pultrusion, SRIM, RTM & VARTM, prepreg
manufacturing, resin powder infusion and rotational molding.
Production of the cyclic oligomers, polymerization, and processing cyclic resins
by a variety of methods will be discussed.
About the Author:
Steve’s composites education began in 1980, as a senior in mechanical
engineering at the Rensselaer Polytechnic Institute. He continued there
through 1981 with a Masters of Science for designing and directing the
construction of an all composite sailplane (the RP-2). After three
years with Exxon, developing a low-cost carbon fiber, Steve returned to RPI
under an Army Fellowship and earned a Ph.D. in mechanical engineering.
He then took a faculty position at RPI for three years, teaching and performing
research in the composites field. Steve started General Composites,
Inc. in 1987, and spun off Global Composites in 1998 in order to focus on the
development of composite products and processes. In 1999 he helped
to found Cyclics Corporation, a company specializing in low viscosity
cyclic thermoplastics. Steve is currently in Technical Marketing for the
Cyclics Corporation.
May 23, 2002
BOSTON SAMPE CHAPTER
GENERAL BUSINESS AND ELECTION OF OFFICERS FOR 2002-2003 SEASON
AGENDA
* Nominations and Election of Officers for 2002-2003 Season
* Treasurer's Report
* Planning for 2002-2003 Season
* Potential Sponsors
* Ideas for Speakers at Monthly Meetings
* General discussion (comments, suggestions, ideas, recommendations, etc.)
The general membership is invited to attend! All members that may be interested
in holding a position on the Board of Directors are encouraged to attend.
April 18, 2002
Student Night UMASS, Students Lowell, MA
Poster Presentations:
Hoop Testing in Composite Flywheel Energy Storage Systems
Modeling of Commingled Glass/Thermoplastic Fabrics for Low Cost/High Volume
Composite Manufacturing
The Effects of Moisture Content and Workhardening on Baseball Bat Performance
Control of Electrospun NanoFiber Morphology and Orientation
Substrate Coating Interactions in /Coated
Fabrics
Using Finite element Method to Model Shear Behavior of Woven Commingled
Glass/Thermoplastic Composites
Constitutive Modeling of Energy Absorbing Foams for Automotive Applications
Modeling of Deformation of Commingled Glass/Thermoplastic Composites
Experimental Examination of Attachment Methods for Composite Sandwich Panels
High Carbon Fly Ash Mixed Thermoplastic
Aggregate for Use in Lightweight Concrete
Nanoclay Modified Elastomers
Impact Modification of Filled Recycled Bottle Grade PET
Properties and Applications of Electrospun Butyl Rubber
Polypropylene and Magnesium Hydroxide-Silane Treated Composites
Models for Military Tank Track Bushings
Development of Thermoplastic Foams for Cable Jacketing Applications
Process Optimization of Molded Thermoplastic Composites
Composites for Bone Tissue Implants
March 21, 2002
Applications of Polymer Layered Silicate Nanocomposites
Speaker:
Dr. Bryan Koene Manager – NanoMaterials Group Triton Systems
200 Turnpike Road Chelmsford, MA 01824
www.tritonsys.com
Triton Systems, Inc. has demonstrated that the
incorporation of well dispersed nanosilicate platelets into various
thermoplastic resins such as polyamides, polyolefins, polyesters, and EVOH
results in dramatically improved gas barrier without adversely affecting the
processibility or mechanical properties of the polymer resin. These high
aspect ratio layers generate a tortuous path for the diffusing species, thus
significantly increasing the diffusion distance through the thickness of the
polymer. In this presentation, we will discuss the improved barrier as
well as thermal and mechanical enhancements of various elastomer nanocomposites.
The processes by which polymer / silicate compatibility are attained through
chemical modification and processing variables will be discussed.
Triton is actively researching several areas of polymer layered silicate
nanocomposites. This research encompasses a wide range of desired
enhancements for gas barrier (O2, H2O, fuel, chemical warfare agents),
thermo-mechanical properties, and ballistic performance.
About the Author:
Dr. Koene is the Manager of the NanoMaterials group at Triton Systems, Inc. in
Chelmsford, Massachusetts, and leads a group of scientists and engineers focused
on nanocomposite research for US Department of Defense as well as commercial
applications. This includes the use of nanocomposites for enhanced gas
barrier (O2, H2O, He), chemical and biological agent resistance, hydrocarbon
fuels, as well as improved thermo-mechanical properties for various
thermoplastic and thermoset polymers.
Dr. Koene received his Ph.D. in Chemistry from the University of Waterloo,
Canada in 1996 with a doctoral thesis entitled “Synthesis and Characterization
of Novel Conductive Transition Metal Oxide / Polymer Nanocomposites”. This
research involved the study of various nanocomposite hybrids between
electronically conductive polymers and transition metal oxides for their use as
anodes or cathodes in secondary electrochemical cells. Following his
doctoral work, Dr. Koene completed a postdoctoral fellowship at the University
of Southern California where he researched inorganic / organic materials for
their use in photovoltaic and light emitting devices. In this project, he
studied energy / electron transfer mechanisms for various optoelectronic
devices.
February 21, 2002
A Description of High Energy and High Power
Composite Flywheel Energy Storage Systems
Speaker:
Mr. Mike Favaloro Beacon Power Corporation, 234 Ballardvale Street Wilmington,
MA 01887
Tel 978/661-2027 favaloro@beaconpower.com
Michael R. Favaloro holds a B.S. in Plastics Engineering from the University of
Lowell. In the late 1970's, Mike worked on compound development of engineering
thermoplastics at GAF in Wayne, N.J. In 1980, he moved to the composites
development group at Avco Systems, where he worked on 2D and 3D carbon/carbon
composites, reinforced teflon radomes, and composite flywheels. From 1983-5, he
was section chief of nosetip, antenna window, and rocket nozzle manufacturing at
Avco. Mike moved to GE Lynn in 1985, where he was involved in the development of
composite applications in aircraft engines, including the graphite/PMR15 outer
bypass duct for the F404. Mike returned to (Avco) Textron in 1987 where he
became program manager and then team leader for the composites engineering team.
His team was instrumental in the development of advanced carbon/carbon
composites, dielectric controlled composites, and inorganic composites for
numerous aerospace applications. In 1996, with the merger of Textron Specialty
Materials into Textron Systems, Mike became Director of the combined composite
business lines of the two divisions, where he was responsible for the P&L of
boron and silicon carbide fiber and prepreg, metal- and ceramic- matrix
composites, and inorganic matrix composites. From 1996-8, the composites
business line grew by 50% sales and 150% profit. As Textron began to sell off
it's materials business lines Mike went to Beacon Power Company in Jan. 2000,
where he is Director, Composites Programs. Mike's team has built a
state-of-the-art characterization facility, and qualified very low cost, high
reliability composite flywheels for this dynamic, highly stressed application.
Mike was the recipient of the annual Textron Excalibur award in 1995. He has
written numerous technical papers, including a chapter on ablative materials for
the Concise Encyclopedia of Chemical Technology, J. Wiley, 1998. He is on the
Board of Advisors for e-composites.com.
January 17, 2002
Carbon Nanotubes
Speaker:
Dr. R. Terry Baker Catalytic Materials, Ltd. 1750 Washington Street, West
Holliston Professional Park Holliston, MA 01746
Established in 1995 to conduct research and
development of nanostructured materials. The company developed "Graphite
Nanofibers", a family of engineered materials produced by the thermal
decomposition of carbon containing gases over selected metal particles. GNF
consist of nanosized graphite layers perfectly stacked at various angles with
respect to the fiber axis. In some structures all edges are exposed, whereas in
others only the basal plane of graphite is exposed. The structure of the
nanofiber is determined by the geometry of the metal catalyst particle. There
are many types of GNF structures including: herring-bone, platelet, tubular, and
a new type of conformation, the so-called "ribbon" structure. This material
possesses many of the properties of the "tubular" form. Due to the presence of
exposed edges functionality can be incorporated making this conformation
chemically active. With this structure CML has been able to overcome the
chemical inertness encountered in carbon nanotubes. GNF possess a combination of
properties rarely found in other materials, i.e. 100% graphite edges, high
surface area and good electrical conductivity. The presence of functional groups
at edge sites makes them suitable for a variety of applications including:
electrodes for fuel cells, hydrogen storage, catalyst supports, conductive
polymers, water purification, and polymer reinforcement
About the author:
Dr. Terry Baker, Vice President for Research, has many years of experience in
the area of catalysis and carbon nanostructures, with over 200 papers published
and 28 patents issued. During his 18 years at AERE Harwell and Exxon's Corporate
Research Laboratory, Dr. Baker pioneered the use of controlled atmosphere
electron microscopy and was the first researcher to observe a catalyst in
action. He proposed a growth mechanism for catalytically formed carbon
nanostructures, which was later refined to include the role of the metal
surfaces in reactions
November 15, 2001 Meeting cancelled
October 18, 2001
Catherine A. Byrne, Ph.D. Senior Research
Scientist, Science Research Laboratory, Inc.
15 Ward Street, Somerville, MA 02143
"E Beam/Thermal Curing of Carbon Fiber
Composites"
Radiation induced polymerization of cationic
epoxy resins can be used for the cure of carbon fiber composites. In the
research to be discussed, the electron beam (EB) curing technique was combined
with a composite fabrication technique called automated tape placement to
demonstrate that ply-by-ply EB curing can be used for preparation of aerospace
composites. The results indicate that a low dose of electron beam radiation
ply-by-ply followed by a thermal postcure is as effective in developing short
beam shear mechanical strength as a high dose of electron beam radiation all at
once after lay-up. Thermal post cure is required for attaining high glass
transition temperature. Electron beams ranging in energy from 200 keV to 4 MeV
are used at Science Research Lab for composite fabrication and other
applications that will be discussed, including adhesive curing and thin film
curing and crosslinking.
About the Author:
Dr. Catherine A. Byrne has over 20 years experience in organic materials
preparation and characterization for military and civilian applications. As a
senior research chemist with the Army Research Laboratory Materials Directorate,
she investigated polymers for applications as composite resins, flexible lenses,
shock absorbing polymers, liquid crystalline materials, chemical agent resistant
coating, photo- and biodegradable materials. Dr. Byrne holds a Ph.D. in
chemistry from the University of Connecticut and did postdoctoral research in
the Department of Polymer Science and Engineering at the University of
Massachusetts at Amherst before joining the Army Research Laboratory. She has
published or presented over 50 technical papers. Dr. Byrne joined SRL in 1996
and has been instrumental in the development of electron beam curable resins for
composites and adhesives. She has used electron beam curing and crosslinking for
a variety of applications, including crosslinking of polymer membranes for waste
water purification and fuel cell membrane electrode assemblies.
SEPTEMBER 20, 2001
Joe Wahl, Raytheon Electronic Systems,
Lexington Laboratory, Lexington , MA
“ALON™ Optical Ceramic for High Performance
Applications”
ALONÔ optical ceramic is a transparent
polycrystalline ceramic material (aluminum oxynitride) that has many optical and
mechanical properties similar to sapphire with many interesting military, law
enforcement, and commercial applications. It demonstrates superior
performance in ballistic tests when used as the hard face of a transparent
laminate. A description of how the transparent ceramic material is made,
current capabilities for size and shape, and the latest optical and mechanical
property data will be presented. A review will be given on the current
status of ALONÔ optical ceramic for demanding aerospace applications. Near
term insertions in missile, airborne and undersea systems, as well as commercial
applications will be covered. The most recent transparent armor ballistic
test results and applications in this unforgiving environment will be presented.
About the author:
Mr. Joseph Wahl is a Principle Scientist and manager of the Advanced Material
Group at Raytheon’s Lexington Laboratories. He received a B.S. and M.S. in
Materials Engineering from Rensselaer Polytechnic Institute in 1978 and 1980,
respectively. Following graduation, Mr. Wahl joined Lockheed Missiles and
Space Company in the Space Systems Division and was involved in the development,
design, and manufacture of advanced composite structures and ceramic based
thermal control systems for spacecraft. He then joined Raytheon’s Research
Division in 1984 and has been involved in the development of ceramic materials
for commercial, high-speed missile, and ballistic applications.
MAY 17, 2001
John D. Tauriello, FiberCote
Industries, Waterbury, CT
A COMPOSITE MATERIAL QUALIFICATION METHOD THAT
RESULTS IN COST, TIME AND RISK REDUCTION
One of the largest single regulatory hurdles
for an airframe manufacturer, i.e., user of polymer based advanced composite
materials in certified aircraft applications, is to generate design allowables
that will satisfy Federal Aviation Regulations (FARs). Due to the lack of
a regulatory mechanism that encourages materials users to share data,
historically each user has independently executed coupon level test plans and
design allowable programs for specific materials - a costly and time consuming
process. Design allowables for similar or identical materials have often
been generated consecutively by several users as sa routine part of their
certification efforts, which has resulted in redundant costs to users, materials
manufacturers and regulators. A new composite materials qualification
methodology has been developed by members of the Advanced General Aviation
Technology Experiments (AGATE) consortium. Based on Military Handbook 17
(MIL-HBK-17) guidelines, the “AGATE Method” describes a “standardized” coupon
level material qualification test plan and statistical technique that yields
lamina design allowables for a specific material system, such that allowables
can be shared among multiple users without each user having to repeat the full
qualification procedure. Once the original qualification data base is
completed and its resultant design allowables are approved for use by the FAA,
each user needs only to perform a limited “equivalency” test plan to verify that
their process yields properties that are equivalent to the original database.
About the Author:
Mr. Tauriello has worked in technical marketing and sales, business development
and management capacities in the advanced composite’s industry for the past 17
years. Mr. Tauriello has a B.A., cum Laude, in Psychology and Chemistry
from Saint John Fisher College.
APRIL 19, 2001
Eric Saarmaa
SMART STRUCTURES AND MATERIALS TECHNOLOGY
This presentation will cover the basic
concepts surrounding smart materials and their use in smart structures. Smart
materials are materials that respond to environmental stimuli and produce
noticeable effects in a timely manner. Stimuli include: strain, stress,
temperature, chemicals, electric fields, magnetic fields, hydrostatic pressure,
radiation forms, and numerous other 'forces'. The useful effects produced by
these stimuli include, but are not limited to color changes, refractive index
changes, stress or strain distribution changes, or volume changes.
Eric Saarmaa has graciously agreed to speak in Dr. James Harvey's absence. Dr.
Harvey is unable to attend due to health concerns.
March 15, 2001
Dennis McGuinness, Lucas Industries,
Springfield, VT
“Innovative Composite Tooling Fabrication”
New material types are being researched and
applied to tooling applications at an ever increasing rate these days. Critical
parameters such as dimensional stability and finish quality that have driven
tool material selection and design in the past are being increasingly combined
with the need to reduce fabrication costs and accelerate delivery schedules.
Although traditional mastering materials such as mahogany, pine, and urethane
modeling stock are still used extensively in the composites industry, newer
material systems that use epoxies, one or two part chemistry and many different
fillers are beginning to supplant these older materials.
As a
custom manufacturer of all types of molds and masters, Lucas Industries has
employed many of the commercially available materials over the past 3 decades.
Customer requirements continually drive the company toward new and innovative
materials and unusual applications of existing materials. The company
recently produced a large mold using a new Aeromark 80 system of modeling paste
with a urethane foam base. All the typical constraints for new composite
projects were evident; short schedule, limited budget, critical areas of contour
accuracy, and dimensional stability to 160°F.
About the Speaker
Dennis McGuinness is the Sales and Marketing Manager for Lucas Industries.
He has over 35 years in the aerospace and specialty machining industries.
Mr. McGuinness has owned and operated several machine and custom fabrication
shops focusing on high quality metal and, more recently, advanced composite
products.
February 15, 2001
DANA M. GRANVILLE, dgranvi@arl.army.mil Deputy Chief, Composites & Lightweight
Structures Branch
U.S. ARMY RESEARCH LABORATORY - Aberdeen Proving Ground, MD 21005
MULTIFUNCTIONAL COMPOSITES FOR ARMY
APPLICATIONS
Meeting or exceeding Army performance requirements with materials that allow
weight reductions of up to 50% are key reasons for composites usage in primary
structures, from munitions to missiles, helicopters and land combat vehicles.
Composites allow designers to tailor directional properties exactly where they
are needed while providing redundant load paths to maintain structural integrity
for weapons platforms damaged in battle. Weight savings in Army structures
also is critical in meeting rapid deployability requirements around the globe.
Mobility, agility, and reduced power consumption are other attributes that are
met using composite structures.
The survivability of the Army warfighter and weapon
platforms depends on protection from detection and from a variety of threats.
Today and in the future, the ability of composites to make Army structures
lighter will not be simply met by material substitution, but by the clever
design and integration of Army-unique features that allow the structure to
perform several functions. As an example, armor used for ground combat
vehicles was considered a “parasitic” weight that was “hung” onto vehicles for
protection, providing only one function – stopping a projectile. New
composite integral armor, using several layers of fiberforms, resins and
ceramic, has been designed to meet that need while also carrying the dynamic
structural loads of the vehicle, resulting in additional weight savings.
This armor has also been designed for improved chemical agent resistance,
fragmentation and spall protection, damage detection, and fire-smoke-toxicity
protection.
Multifunctionality also serves to reduce the “Logistics
Tail” through reduced numbers of assemblies and subassemblies, meaning that
there will be fewer parts to replace and a lower likelihood that weapons
platforms will be out of service. Composite materials and innovative
design allows the dramatic reduction and even the elimination of fasteners for
applications such as integral armor for land combat vehicles, and one-piece
net-shape fuselages for helicopters. These features, along with the
ability to embed sensors within composites to monitor structural integrity and
real-time battle damage means lower overall sustainment / life-cycle costs for
systems that may remain in the Army inventory for 40 years or more.
This paper will discuss multifunctional composites for
a variety of future Army applications, with a focus on composite armor material
selection, design and manufacturability.
About the Author
Education: B.S., Plastics Engineering, Lowell Tech '75, and graduate
work at UMASS-Lowell and Boston University.
Experience: Mr. Granville has over 25 years experience in composite
materials processing at the Army Research Laboratory, Aberdeen Proving Ground,
MD, formerly known as the Materials Technology Laboratory and the Army Materials
and Mechanics Research Center, Watertown, MA. He has served on Army aviation
review boards for CH-47, AH-1, ACAP, and RAH-66 (Comanche) helicopters, as
well as technical programs supporting the Army's commodity commands, most
recently in thick composite armor development for the Tank-Automotive Command,
and light armor/fire protection for Natick Soldier Center's "National Protection
Center". He is currently the Army Composites Manufacturing Science and
Technology manager for Army Material Command-headquarters, and participates on
several DoD materials committees including JDL Reliance, MIL HANDBOOK and the
Navy Center of Excellence for Composites Mfg (CECMT) technical advisory board.
He also serves as a trustee to the Plastics Institute of America (PIA) at UMASS-Lowell's
Institute for Plastics Innovation.
January 18, 2001
Jiri George Drobny Drobny Polymer Associates,
Merrimack/USA
COMPOSITES BASED ON FLUOROPOLYMERS
Fluoropolymers are a specialized group of
polymeric materials with some unique properties. Their chemistry is
derived from the compounds used in the refrigeration industry. Since the
discovery of polytetrafluoroethylene (PTFE) by Plunkett in 1938 a large number
of new types of fluorine containing polymers has been developed and a relatively
high proportion of that in the last two decades. Some of them are
derivatives from the original PTFE; some contain other elements, such as
chlorine, silicon, or nitrogen. Current worldwide production capacity for
fluoropolymers is about 135,000 metric tons and approximately 60% of that is for
polytetrafluoroethylene. Overall annual growth of production of fluoropolymers
is in the 6 to 7% range. Roughly half of the fluoropolymers is used in
electrical and electronic applications
Because of their molecular structure, fluoropolymers, notably perfluoropolymers
(PTFE and PFA) have exceptionally high melting points and thermal stability. In
general, most fluoropolymers exhibit a very high resistance to common solvents
and aggressive chemicals, some are excellent dielectrics. Perfluoropolymers,
particularly PTFE have a serious weakness, namely considerable flow under a
sustained load. This can be greatly reduced by the addition of mineral
reinforcing fillers such as chopped glass fibers, bronze or graphite particles.
Typical composite structures made from fluoropolymers are coated woven and
nonwoven fabrics and laminates from them, composite films and sheeting
consisting of films from different polymers and foils and certain specialty
coatings. Such composites find use in construction, electrical and electronic
industries, in automotive industry, in aviation and aerospace, in food
processing and chemical process industries, in military applications and many
others.
About the Author
Jiri George Drobny, native of the Czech Republic was educated at the Technical
University in Prague in Chemical Engineering, specializing in processing of
plastics and elastomers and at the Institute of Polymer Science of the
University of Akron in Physics and Engineering of Polymers. He also earned an
MBA in Finance and Management at Shippensburg State University in Shippensburg,
PA. His career spans over 40 years in the polymer processing industry in Europe,
the US and Canada, mainly in R&D with senior and executive responsibilities.
Currently, he is President of Drobny Polymer Associates an international
consulting firm specializing in fluoropolymer science and technology, radiation
processing and elastomer technology. Mr. Drobny is also active as an educator,
author, and as technical and scientific translator. He is member of the
Association of Consulting Chemists and Chemical Engineers, Society of Plastic
Engineers, American Chemical Society and SAMPE and is listed in Who’s Who in
America, Who’s Who in Science and Engineering and Who’s Who in the East. He
resides in New Hampshire.
October 19, 2000
Armor Systems
Speaker: Philip Cunniff
BS in engineering from the University of Portland, Oregon
14 years experience in armor systems
Member of the Executive Steering Committee of the Ballistics Division of NDIA
Recipient of the 1999 Zerno Award for the Most Recent Contribution to
Fundamental Ballistics
Phil works in the design and deployment of personnel armor systems at:
U.S. Army Soldier and Biological Chemical Command
Soldier Systems Center-Natick
Natick, Mass. 01760-5019
508-233-5463
ABSTRACT:
Armor systems are designed using an unusual set of requirements; unlike most
systems, the important function of armor occurs during incipient failure. The
design challenge includes analysis of dynamically loaded anisotropic materials
at extremely high strain rates accompanied by material failure.
Following an overview of existing armor systems and impact phenomenology, Mr.
Cunniff will discuss recent developments in armor technology by the U.S. Army.
These will include performance indicators, analysis tools and design procedures
for armor applications and materials.
April 20, 2000
Ralph Langensiepen, Fiber Materials, Inc.
A video enhanced presentation on
"Carbon/Carbon Composites; Development and Testing of Rocket Engine Nozzles".
February 17, 2000
Tim Dominick, Fiber Materials, Inc.
The design, development, and demonstration of an advanced composite shroud
assembly has been conducted for the US Army Space and Missile Defense Command.
A presentation will be provided which includes the design efforts conducted and
emphasis on the interactive effects of the design for successful shroud
deployment. Component fabrication, sub-assembly and assembly test and
evaluation will be shown.
Shroud
materials and components consist of a multidirectional reinforced quartz nosetip,
a low-cost braided heatshield, OMC substructure which incorporates a syntactic
foam core, and a steel bladder deployment system. Development of components and
preparation of the shroud for flight-testing will be presented.
November 18, 1999
Mike Burkitt, J. D. Lincoln Incorporated
"Thin Film Technology"
With more emphasis
being placed on smaller and lighter weight products, the J. D. Lincoln,
Incorporated, company has worked to develop new products utilizing thin film
technology. Adhesive films, facesheets, coated films and substrates
provide the designer a wide variety of products for new designs in aerospace,
electronics and other related industries.
Starting with “bond aid” in 1984 and continuing through
today with epoxy, phenolic, cyanate ester and polyimide thin films, the customer
has driven the development of many new products. Unique applications in
aircraft interiors, automotive, ballistics, electronic flex circuits, medical,
sporting goods and many more have utilized these thin films to achieve levels of
performace not available in the past.
Mike Burkitt, Vice-President, J.D. Lincoln
Incorporated, has a degree in Engineering Physics and has been in the composites
industry for 34 years.
October 21, 1999
David Shepard, Holometrix Micromet
"In-Process Cure Monitoring Utilizing
Dielectric Sensors"
Dielectric measurements are widely used for the cure monitoring of thermosetting
resins and composites. The ability to implant disposable dielectric
sensors within a part or install permanent dielectric sensors in a mold wall or
two, makes dielectric cure monitoring a very versatile in-process cure
monitoring technique.
This presentation will discuss the fundamentals of dielectric cure monitoring,
correlation of the data to other measurement techniques, and applications of the
technique in the processing of advanced composites.
Sept. 16, 1999
Steve Driscoll, Department of Plastics Engineering, University of Massachusetts
at Lowell
"Problem Solving with Rheology"
The global use of rheological protocols for
solving manufacturing problems has been widely documented for many years.
This presentation will explore briefly these testing techniques, review examples
of the type of data generated, and case studies will be discussed to illustrate
how rheology can be a very cost-effective problem solver. Comments will focus on
monitoring the flow behavior of thermosetting neat resins and pastes, the cure
behavior of prepregs, and the effect of rubber tougheners, curing agents, and
fiber reinforcement orientation on the functional properties of the cured solid
product.
Updated: 2008-08-19