HANDBOOK OF

COMPOSITES
HANDBOOKOF
COMPOSITES

SECOND EDITION

Edited by

S.T. Pe ters
Process Research, Mountain View, California, USA

la ni SPRINGER-SCIENCE+BUSINESS MEDIA, B.V.

First edition 1982

Second edition 1998

© 1998 Springer Science+Business Media Donlrecht

Originally published by Chapman & Hall in 1998
Softcover reprint ofthe hardcover 2nd edition 1998
Thomson Science is a division of International Thomson Publishing

Typeset in 10/12 pt Palatino by GreenGate Publishing Services, Tonbridge, Engiand

ISBN 978-0-412-54020-2 ISBN 978-1-4615-6389-1 (eBook)

DOI 10.1007/978-1-4615-6389-1

All rights reserved. No part of this publication may be reproduced, stored in a

retrieval system or transmitted in any form or by any means, electronic, mechanical,
photocopying, recording or otherwise, without the prior written permission of the
publishers. Applications for permission should be addressed to the rights manager
at the London address of the publisher.
The publisher makes no representation, express or implied, with regard to the
accuracy of the information contained in this book and cannat accept any legal
responsibility or liability for any errors or omissions that may be made.

A catalogue record for this book is available from the British Library
CONTENTS

Contributors ix

Preface xv

About the editor xvi

Foreword xvii

Acknowledgements xviii

Introduction, composite basics and road map 1

S.T. Peters
1 Overview of composite materials 21
Theodore]. Reinhart

PART ONE: BASIC MATERIALS

Polymeric matrix systems
2 Polyester and vinyl ester resin 34
Frank A. Cassis and Robert C. Talbot
3 Epoxy resins 48
L.S. Penn and H. Wang
4 High temperature resins 75
Hugh H. Gibbs
5 Speciality matrix resins 99
David A. Shimp
6 Thermoplastic resins 115
Lars A. Berglund

Reinforcements and composites

7 Fiberglass reinforcement 131
Dennis J. Vaughan
vi Handbook of composites

8 Boron, high silica, quartz and ceramic fibers 156

Anthony Marzullo
9 Carbon fibers 169
Khalid Lafdi and Maurice A. Wright
10 Organic fibers 202
Linda L. Clements
11 Particulate fillers 242
Harry S. Katz
12 Sandwich construction 254
Andrew C. Marshall
13 Metal matrix composites 291
VJ. Kostikov and V.S. Kilin
14 Ceramic composites 307
M.F. Amateau
15 Carbon-carbon composites 333
John D. Buckley

PART TWO: PROCESSING METHODS

General composites and reinforced plastics
16 Hand lay-up and bag molding 352
D.R. Sidwell
17 Matched metal compression molding of polymer composites 378
Enamul Haque and Burr (Bud) L. Leach
18 Textile preforming 397
Frank K. Ko and Ceorge W. Du
19 Table rolling of composite tubes 425
John T. Kanne and Jerome S. Berg
20 Resin transfer molding 433
Lihwa Fong and S.C. Advani
21 Filament winding 456
Yu.M. Tarnopol'skii, S.T. Peters, A.I. Bei!,
22 Fiber placement 476
Don O. Evans
23 Pultrusion 488
Brian A. Wilson
24 Processing thermoplastic composites 525
James L. Throne
 Contents vii

Advanced composites
25 Tooling for composites 556
Jerry L. Cadden and Paul F. Sadesky
26 Consolidation techniques and cure control 576
Zhong Cai and Timothy Gutowski
27 Composite machining 596
Kent E. Kohkonen and Nitin Potdar
28 Mechanical fastening and adhesive bonding 610
D. W. Oplinger
29 Surface preparations for ensuring that the glue will stick in bonded
composite structures 667
L.J. Hart-Smith, D. Brown and S. Wong

PART THREE: DESIGN AND ANALYSIS

30 Laminate design 686
Jocelyn M. Seng
31 Design of structure with composites 709
F.J. Schwan
32 Analysis methods 736
v.v. Vasiliev
33 Design allowables substantiation 758
Christy Kirchner Lapp
34 Mechanical tests 778
Yu.M. Tamopol'skii and v.L. Kulakov

PART FOUR: ENVIRONMENTAL EFFECTS

35 Durability and damage tolerance of fibrous composite systems 794
Ken Reifsnider
36 Environmental effects on composites 810
Ann F. Whitaker, Miria M. Finckenor, Harry W. Dursch, R.c. Tennyson
and Philip R. Young
37 Safety and health issues 822
Jennifer A. Heth
38 Nondestructive evaluation methods for composites 838
Thomas S. Jones
39 Repair aspects of composite and adhesively bonded aircraft structures 857
Anton L. Seidl
40 Reuse and disposal 883
Harry E. Pebly
viii Handbook of composites

PART FIVE: APPLICATIONS

41 Land transportation applications 905
Douglas L. Denton
42 Marine applications 916
Wayne C. Tucker and Thomas Juska
43 Commercial and industrial applications of composites 931
Stewart N. Loud
44 Composite biomaterials 957
Shalaby W. Shalaby and Robert A. Latour
45 Scientific applications of composites 967
Vicki P. McConnell
46 Construction 982
Ever J. Barbero
47 Aerospace equipment and instrument structure 1004
Gary C. Krumweide and Eddy A. Derby
48 Aircraft applications 1022
Richard N. Hadcock
49 Composites in the sporting goods industry 1044
Brian E. Spencer

APPENDICES
Appendix A
Typical properties for advanced composites 1053
Kenneth R. Berg
Appendix B
Specifications and standards for polymer composites 1059
Frank T. Traceski
Index 1069
CONTRIBUTORS

SURESH G. ADVANI KENNETH R. BERG

Department of Mechanical Engineering, Riggs Corporation,
University of Delaware, 837 Agate Street,
Spencer Laboratory, Medford, OR 97501,
Newark, DE 19716, USA
USA
LARS A. BERGLUND
MAURICE F. AMATEAU Lulea University of Technology,
Applied Research Laboratory, SE-971 87 Lulea,
Pennsylvania State University, Sweden
PO Box 30,
State College, PA 16804, D.BROWN
USA Boeing Commercial Airplane Group,
Douglas Products Division,
EVER J. BARBERO Mail Stop DOOI-0018,
315 Engineering Science Building, Long Beach, CA 90846,
West Vll'ginia University, USA
Morgantown, WV 26506-6106,
USA JOHN D. BUCKLEY
23 East Governor Drive,
A.I. BElL' Newport News, VA 23602,
Institute of Polymer Mechanics, USA
Latvian Academy of Sciences,
23 Aizkraukles Street, JERRY L. CADDEN
Riga LV-I006, C & S Technologies,
Latvia 42759 Mountain Shadow,
Murrieta, CA 92562,
JEROME S. BERG USA
True Temper Sports,
5421 Avenida Encinas, ZHONG CAl (deceased)
Suite G, 4180 Berkeley Creek Drive,
Carlsbad, CA 92008, Duluth, GA 30136,
USA USA
x Handbook of composites

FRANK A. CASSIS MIRIA M. FINCKENOR

FAC Associates, EH12 Bldg 4711,
1150 N. Mountain, Suite 102B, Marshall Space Flight Center,
Upland, CA 91786, AL35812,
USA USA

LINDA L. CLEMENTS LIHWAFONG

C & C Technologies,
PO Box 1089,
Dayton, NY 89403,
USA
DOUGLAS L. DENTON
Chrysler Corporation,
CIMS 482-00-13,
800 Chrysler Drive,
Auburn Hills, MI 48326-2757,
USA
EDDY A. DERBY
Composite Optics,
9617 Distribution Ave,
San Diego, CA 92121,
USA
GEORGEW.DU
Principal Engineer,
16331 Bay Vista Drive
Clearwater, FL 34620,
USA
HARRY W. DURSCH
Boeing Defense and Space Group,
PO Box 3999, Mail Stop 73-09,
Seattle, WA 98124-2846,
USA
DONO. EVANS
Cincinnati Milacron,
4701 Marburg Avenue,
Cincinnati, Ohio 45209,
USA
BLKG5,
Nanyang Avenue,
Singapore 63616
HUGH H. GIBBS
Polycomp Consulting, Inc.,
25 Crestfield Road,
WIlmington, DE 19810,
USA
TIMOTHY GUTOWSKI
Department of Mechanical Engineering,
Massachusetts Institute of Technology,
Bldg 35-234,
Cambridge, MA 02139,
USA
RICHARD N. HADCOCK
6 Sue Circle,
Huntington, NY 11743,
USA
ENAMUL HAQUE
Azdel, Inc.,
Technology Center,
658 Washburn Switch Road,
Shelby, NC 28151-2284,
USA
L.J. HART-SMITH
Boeing Commercial Airplane Group,
Douglas Products Division,
Mail Stop 0800-0019,
4000 Lakewood Boulevard,
Long Beach, CA 90846,
USA
 Contributors xi

JENNIFER HETH VALERY I. KOSTIKOV

Cytec Fiberite, Niigrafit Institute,
501 W. Third Street, 2 Electrodonaya Street,
Winona, MN 55987-2854, Moscow, 111524,
USA Russia

THOMAS S. JONES GARY C. KRUMWEIDE

Industrial Quality, Inc., Composite Optics,
640 E. Diamond Ave., Suite C, 9617 Distribution Avenue,
Gaithersburg, MD 20877, San Diego, CA 92121,
USA USA

THOMAS JUSKA v.1. KULAKOV

Naval Surface Warfare Center, Institute of Polymer Mechanics,
Carderock Division, Latvian Academy of Sciences,
Structures and Composites Department, 23 Aizkraukles Street,
Bethesda, MD 20084-5000, Riga LV-1006,
USA Latvia

JOHN T. KANNE KHAUD LAFDI

2201 Johnson Road, Center for Advanced Friction Studies,
Memphis, TN 38139, Southern lllinois University at Carbondale,
USA Carbondale, IL 62901-4343,
USA
HARRY S. KATZ
Utility Development Corporation, CHRISTY KIRCHNER LAPP
112 Naylon Avenue, 1412 Bellingham Way,
Livingston, NJ 07039, Sunnyvale, CA 94087,
USA USA

V.S. KILIN ROBERT A. LATOUR

Niigrafit Institute, Clemson University,
2 Electrodonaya Street, Clemson, SC 29634,
Moscow, 111524, USA
Russia
BURR 1. LEACH
FRANKK.KO Cambridge Industries,
Drexel University, 1700 Factory Avenue,
Fibrous Materials Research Laboratory 27-439, Marion, IN 46952,
Philadelphia, PA 19104, USA
USA
STEWART N. LOUD
KENT E. KaHKONEN Composites Worldwide Inc.,
Brigham Young University, 991 Lomas Santa Fe Drive, C469,
435 CTB Technology Department, Solana Beach, CA 92075-2125,
Provo, ur 84602, USA
USA
xii Handbook of composites

VICKI P. MCCONNELL NITIN POTDAR

Ray Publishing, Brigham Young University,
Independence Street, 435 CTB Technology Department,
Suite 270, Wheat Ridge, Provo, UT 84602,
CO 80033, USA
USA
KENNETH REIFSNIDER
ANDREW C. MARSHALL Virginia Polytechnic Institute and State
Marshall Consulting, University,
720 Appaloosa Drive, Patton Hall 120,
Walnut Creek, CA 94596, Blacksburg, VA 24061-0219,
USA USA

ANTHONY MARZULLO THEOOORE J. REINHART

39 Harold Street, 345 Forrer Boulevard,
Cos Cob, CT 06807-2132, Dayton, OH 45419-3238,
USA USA

OONALD W. OPLINGER PAUL F. SADESKY

Federal Aviation Administration, C & S Technologies,
Wm. J. Hughes Technical Center AAR-431, 23547 Mountain Court,
Atlantic City, International Airport, Murrieta, CA 92562,
NJ 08405, USA
USA
FRANK J. SCHWAN
HARRY E. PEBLY 36671 Montecito Drive,
198 Center Grove Road, Fremont, CA 94536,
Randolph, NJ 07869, USA
USA
ANTON L. SEIDL
LYNNS.PENN 18941 Mellon Drive,
Department of Chemical and Materials Saratoga, CA 95070,
Engineering, USA
177 Anderson Hall,
University of Kentucky, JOCELYN M. SENG
Lexington, KY 40506-0046, Owens Corning Science and Technology
USA Center,
2790 Columbus Road,
S.T. PETERS Granville, OH 43023-1200,
Process Research, USA
925 Sladky Avenue,
Mountain View, CA 94040-3625, SHALABY W. SHALABY
USA Clemson University,
301 Rhodes Res.,
Clemson, SC 29634,
USA
 Contributors xiii

DAVIDA. SHIMP WAYNE C. TUCKER

PO Box 974, Naval Undersea Warfare Center,
Prospect, KY 40059, PO Box 86,
USA Exeter, RI 02822,
USA
DONALD R. SIDWELL
44609 Grove Lane, V. V. VASILIEV
Lancaster, CA 93534-2833, Moscow State University,
USA 14-1-110 Podolskih Kursantov Street,
Moscow 113545,
BRIAN E. SPENCER Russia
Spencer Composite Corporation,
3220 Superior Street, PO Box 4377, DENNIS J. VAUGHAN
Lincoln, NE 68504-0377, 146 Longview Drive,
USA Anderson, SC 29621,
USA
ROBERT C. TALBOT
7199 Lorine Court, H.WANG
Columbus, OH 4323~5125, Department of Chemical and Materials
USA Engineering,
177 Anderson Hall,
YU.M. TARNOPOL'SKll University of Kentucky,
Institute of Polymer Mechanics, Lexington, KY 40506-0046,
Latvian Academy of Sciences, USA
23 Aizkraukles Street,
Riga LV-1006, ANN F. WHITAKER
Latvia EH01 Bldg 4612,
Marshall Space Flight Center,
R.c. TENNYSON AL35812,
University of Toronto, USA
Institute for Aerospace Studies,
4925 Dufferin Street, BRIAN A. WILSON
Downsview, Ontario, Wilson Composite Group,
Canada M3H 5T6 6611 Folsom-Auburn Road, Suite C,
Folsom, CA 95630,
JAMES L. THRONE USA
Sherwood Technologies, Inc.,
158 Brookside Boulevard, S.WONG
Hinckley, OH 44233-9676, Boeing Commercial Airplane Group,
USA Douglas Products Division,
Mail Stop DOOl-0018,
FRANK TRACESKI Long Beach, CA 90846,
Department of Defense, USA
5203 Leesburg Pike Suite 1403,
Falls Church, VA 22041,
USA
xiv Handbook of composites

MAURICE A. WRIGHT PHILIP R. YOUNG

Center for Advanced Friction Studies, Emory & Henry College,
Southern lllinois University at Carbondale, Department of Chemistry,
Carbondale, IL 62901-4343, Emory, VA 24327,
USA USA
PREFACE

Today, fiber reinforced composites are in use • properties of different component (fiber,
in a variety of structures, ranging from space- matrix, filler) materials;
craft and aircraft to buildings and bridges. • manufacturing techniques;
This wide use of composites has been facili- • analysis and design;
tated by the introduction of new materials, • testing;
improvements in manufacturing processes • mechanically fastened and bonded joints;
and developments of new analytical and test- • repair;
ing methods. Unfortunately, information on • damage tolerance;
these topics is scattered in journal articles, in • environmental effects;
conference and symposium proceedings, in • health, safety, reuse, and disposal;
workshop notes, and in government and com- • applications in:
pany reports. This proliferation of the source - aircraft and spacecraft;
material, coupled with the fact that some of - land transportation;
the relevant publications are hard to find or - marine environments;
are restricted, makes it difficult to identify and - biotechnology;
obtain the up-to-date knowledge needed to - construction and infrastructure;
utilize composites to their full advantage. - sporting goods.
This book intends to overcome these diffi-
Each chapter, written by a recognized expert,
culties by presenting, in a single volume,
is self-contained, and contains many of the
many of the recent advances in the field of
'state-of-the-art' techniques reqUired for prac-
composite materials. The main focus of this
tical applications of composites. Thus, this
book is on polymeric matrix, metal matrix,
book should serve as a useful source of infor-
and ceramic matrix composites. The book
mation for practicing engineers and
treats a wide range of subjects. The topics, pre-
specialists, as well as for workers new to this
sented in 49 chapters and two appendices
field.
include:
George S. Springer
• overview of composite material systems
and products;
ABOUT THE EDITOR
S.T. Peters was previously a fellow engineer
with Westinghouse Electric Corporation,
Marine Division prior to devoting full time to
composite and materials and processing con-
sulting for his own company, Process
Research, in Mountain View, CA. He has writ-
ten many articles on composites and filament
winding, a book on filament winding, edited
one previous book and holds several patents
on winding techniques and composite joints.
He is a private consultant with worldwide
clients and has presented tutorials on compos-
ites to many audiences, including the US
Navy and NASA, several technical societies
and two universities. He is a licensed profes-
sional engineer in the state of California, a
member of ASM, and the composites division
of SME and has been elected a fellow of
SAMPE.
FOREWORD
Composites have emerged as a valuable class
of engineering materials because they offer
many attributes not attainable with other
materials. Light weight, coupled with high
stiffness, and selectable properties have fos-
tered their use for many years in satellites,
high performance aircraft and world class sail-
boats as well as submarines. Now, these
materials demonstrate their worth in the mun-
dane, but equally as demanding, consumer,
infrastructure, and sporting goods arenas.
However, the transition to many of these con-
sumer and infrastructure-relat¢d arenas has
been slow, primarily due to the l,ack of under-
standing, the lack of validated data, absence of
design allowables, lack of clear guidelines,
limited hands-on experience, low confidence
and less than optimum supplier data sheets. It
is hoped that this book, crafted by well known
contributors, pre-eminent in their field, mem-
bers of international universities, industrial
research organizations, and government labs
will remedy some of these weak areas and that
this edition will continue as the primary refer-
ence in the composites field and as basic a text
for educational uses as was the first edition.
The editor of the first edition, George
Lubin, was a valued mentor to many, includ-
ing the present editor. This book carries on the
legacy he started: that of a compact but thor-
ough sourcebook, with validated, useful data
to increase understanding, incorporating
application guidelines, fabrication methods
and tradeoffs, basic polymer information and
design recommendations. The successful,
cost-effective fabrication of composite struc-
tures requires utmost cooperation between the
various design and manufacturing specialties
and is one of the prime drivers for' concurrent
engineering'. The needs of concurrent engi-
neering require all contributors to a successful
composite structure design to have some
knowledge of composites. It is hoped that this
handbook will facilitate the acquisition of that
knowledge.
There is little change in scope or objectives
from the first edition, but many changes in
content. Organic matrix composites are still
highlighted and a limited treatment of metal
matrix, carbon and ceramic matrix compos-
ites, as well as treatment of the new polymers,
including the thermoplastic materials have
been added.
The treatment of processing methods has
been expanded for reader convenience, dou-
bling the previous number of chapters. The
structural efficiency of a composite structure is
often determined by its joints, not by its basic
structure. Thus, an extensive treatment of
composite surface treatment, mechanical fas-
tening, and adhesive bonding, which continue
to be important, sometimes vexing areas of
concern in composite structure fabrication,
have been added.
The analysis section has been expanded
with chapters dealing with laminate design,
composite structure design and a new, impor-
tant subject, design allowables substantiation.
There are new chapters on repair, safety and
reuse of composites as well as chapters on the
applications of composites to medical, con-
struction and sporting goods uses that reflect
current concerns and important new uses for
composite materials.
S.T. Peters
ACKNOWLEDGEMENTS
As with any large undertaking there is a sup-
porting group of people without whose help
the objective would not be met. I wish to
acknowledge my wife, Lynn, for her help in
deciphering and rewriting some of the articles
and for enduing my sometimes uncivil
approach to resolving problems. Thanks also
go to Mr Frank Hell and Dr Alvin Nakagawa
of Westinghouse Electric, Marine Division
(now Norton Grumman) for their editorial
and review help. I also wish to thank Dr Linda
Clements for her advice and support.