JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 49

properties to fabricate the tray arms. They tested the load-withstanding capability of these tray arms using a custom-built testing system and found that almost all the parts failed in a narrow load range (60 to 80 lbf) irrespective of the strength of the materials, indicating that the material properties were not efficiently transferring to the tray arms. Vaupell approached SABIC Innovative Plastics to develop a tray arm capable of withstanding a peak load of 120 lbf or higher using SABIC Innovative Plastics resins.

Experimental
Materials Two compounds were developed from SABIC Innovative Plastics Ultem* PEI resin and aerospace-grade carbon fibres. They contained 30 wt% and 40 wt% of fibre reinforcement (Thermocomp* EC006PXQ and EC008PXQ, respectively). The compounds also contained proprietary additives that improved the flow and OSU heat release performance while boosting the mechanical properties. Both materials have excellent FST (flame-smoke-toxicity) properties and are FAR 25.853 compliant. In addition to the PEI-carbon fibre compounds, 30 wt% and 40 wt% carbon fibre-filled PPS compounds (Thermocomp OC006XXQ and OC008XXQ, respectively) were used in this study to compare their performance in the tray arms with the EC006PXQ and EC008PXQ materials.

Fig. 2: (a) Tray arm test setup with a modified MTS system; (b) orientation of the tray arm between the fixtures

Fig. 3: Boundary conditions used in the FEA of the tray arms

Table 1 compares the tensile properties of Thermocomp EC006PXQ, EC008PXQ, OC006XXQ and OC008XXQ materials with die-cast aluminium (7075-O) and machined aluminium (7075-T6). Data in Table 1 indicates that EC006PXQ and EC008PXQ materials are about 50% lighter than aluminium. They have a higher tensile strength than die-cast aluminium (7075-O) and their strength-to-weight ratio is comparable to machined aluminium (7075-T6). The stiffness-to-weight ratio of the EC008PXQ material is comparable to aluminium.

a bottom and a top fixture and pins. The top fixture was also attached to the load cell of the MTS system. The tray arm was supported by an 8-mm metallic pin support, simulating the actual tray arm setup in the aircraft. The orientations of the tray arm in the MTS system are shown in Figure 2(b).

Finite element analysis The Abaqus finite element analysis (FEA) software was used for simulating the loads, boundary conditions and resulting stresses and deflections on the design geometry of the tray arm. Non-linear geometric effects and non-linear material properties Tray arm test set-up were considered. The Thermocomp EC008PXQ compound was A modified MTS system (Instron) was used to test the materials modelled as an isotropic elastic material using the data from the (Figure 2). The tray arm was attached to the MTS system with stress-strain curve of this material. For boundary conditions (how the part is supported and Table 1: Tensile properties of LNP Thermocomp* EC006PXQ, EC008PXQ, OC006XXQ and OC008XXQ comconstrained), the tray table arm pounds and different aluminiums (Al) rested on the pin at the bottom Al Al and a vertical load of 120 lbf was Unit EC006PXQ EC008PXQ OC006XXQ OC008XXQ (7075-O) (7075-T6) applied on the top end. The boundary conditions are illustrated in 2.81 2.81 1.39 1.44 1.41 1.46 Specific gravity Figure 3. Tensile modulus, +23°C GPa 71.7 71.7 30.4 38.6 34 41.3
Tensile strength, +23°C Stiffness-to-weight ratio Strength-to-weight ratio

MPa -

228 25.5 81.1

572 25.5 203.6

288 21.9 207.2

272 26.8 188.9

234 24.1 166.0

190 28.3 130.1

The benefit of FEA is that it shows the locations of stress in the part, especially around pin-loaded holes,

No70 January - February 2012 /

jec composites magazine 49



JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012

Cover
Edito
Point of view: Lanxess, the only fully integrated producer of glass reinforced thermoplastic
Contents
Agenda of Events
COMPANY & BUSINESS
- In Brief - Hexcel to commission two new carbon fibre production lines
- Core materials - Celebrating 25 years of ideas
- Fabrics - Diatex, a generation of growth
APPLICATIONS
- Motorbike - Brammo Empulse uses prepreg to drop weight
- Automotive - A revolution e-mobile concept car
- Automotive - Composite manufacturing simulation to drive process and design innovation
- Housing - A school made entirely of composites for 200 children
MARKET
- Wind - Double-digit growth for global wind O&M market
- China - «Companies with weak R&D capabilities will find it difficult to survive in the future»
- Certification - Rescoll qualified by Airbus for tests on composites
- Human ressources - CEO, designing strategy and corporate vision
FEATURE WIND ENERGY
- Resin - Polyurethane composites for wind turbine blades
- Prepreg - New best-in-class 10-kW wind turbine
- Trend - Composites in wind energy
- Design - Innovative design attempts for large-scale wind turbine blades
- Offshore - Vertiwind and Winflo, two projects for floating offshore wind turbines
RESEARCH & DEVELOPMENT
- Thermoplastics - Study of metal replacement with poly-etherimide/carbon fibre compounds in air-craft food tray arms
- Welding - Optimizing ultrasonic welding of carbon fibrereinforced polyetherimide
TECHNOLOGY & INNOVATIONS
- Innovation
- NDT - Health monitoring assessment and non-destructive inspection of composite structures for surface transport applications
- Manufacturing - Composites are the materials for the future
Index
In the world
Asia: 4 conferences
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Cover
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 2
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Edito
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Point of view: Lanxess, the only fully integrated producer of glass reinforced thermoplastic
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 5
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Contents
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 7
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Ad1
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Ad2
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - In Brief - Hexcel to commission two new carbon fibre production lines
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Core materials - Celebrating 25 years of ideas
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 11
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Fabrics - Diatex, a generation of growth
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Motorbike - Brammo Empulse uses prepreg to drop weight
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Automotive - A revolution e-mobile concept car
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 15
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Automotive - Composite manufacturing simulation to drive process and design innovation
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Housing - A school made entirely of composites for 200 children
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 18
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Wind - Double-digit growth for global wind O&M market
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 20
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - China - «Companies with weak R&D capabilities will find it difficult to survive in the future»
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 22
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 23
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Certification - Rescoll qualified by Airbus for tests on composites
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Human ressources - CEO, designing strategy and corporate vision
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 26
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 27
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 28
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Resin - Polyurethane composites for wind turbine blades
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 30
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 31
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 32
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 33
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 34
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Prepreg - New best-in-class 10-kW wind turbine
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Trend - Composites in wind energy
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 37
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 38
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Design - Innovative design attempts for large-scale wind turbine blades
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 40
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 41
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 42
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 43
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 44
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 45
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Offshore - Vertiwind and Winflo, two projects for floating offshore wind turbines
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 47
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Thermoplastics - Study of metal replacement with poly-etherimide/carbon fibre compounds in air-craft food tray arms
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 49
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 50
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 51
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 52
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 53
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Welding - Optimizing ultrasonic welding of carbon fibrereinforced polyetherimide
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 55
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 56
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 57
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 58
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Innovation
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - NDT - Health monitoring assessment and non-destructive inspection of composite structures for surface transport applications
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 61
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 62
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 63
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - - Manufacturing - Composites are the materials for the future
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Index
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - In the world
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - Asia: 4 conferences
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 68
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 69
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 70
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 71
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 72
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 73
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 74
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 75
JEC COMPOSITES MAGAZINE - Issue #70 - January/February 2012 - 76
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