Aerogel core CFRP curved sandwich composites with variable cross-section without ply-drop for body protection and rehabilitation

Ammasai Sengodan, G ORCID: https://orcid.org/0000-0002-3256-0534 and Joshi, SC 2016, Aerogel core CFRP curved sandwich composites with variable cross-section without ply-drop for body protection and rehabilitation , in: SAMPE Long Beach 2016 Conference and Exhibition, 23 May 2016 - 26 May 2016, Long Beach, United States.

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Abstract

A novel method to design and manufacture aerogel core (patented technology) CFRP sandwich composites with variable geometry and mechanical properties without any ply-drop is envisaged, analyzed and demonstrated. Using this method, such composites can be designed optimally beforehand with targeted local variations in properties and geometry as required for many sports and leisure equipment, safety guards and rehabilitation goods. A two-step procedure is proposed to manufacture curved sandwich panels with CFRP prepreg face sheets and customized silica aerogel core. During the first step, two face sheet prepreg lay-ups with uniform cross-sectional area (prismatic) are compacted at their minimum viscosity state under variable pressure in a hot press to produce CFRP laminates with variable cross-sectional area (or taper) as required. In the second step, pre-fabricated silica aerogel core is placed in between the already tapered face sheets, followed by vacuum bagging and curing in an autoclave/oven. CFRP provides high specific strength and stiffness. The silica aerogel core is lightweight (a 30,000 mm3 aerogel core weighs only 6.5 g) and hydrophobic with a compressive strain recovery of 80%. This combination of CFRP and aerogel core is expected to provide highly lightweight product with excellent and optimized stiffness variation as well as necessary impact absorption properties. In this study, a combination of virtual design and actual manufacturing exercise, and its outcome are offered to understand the fabrication process and special features of the final product.

Item Type: Conference or Workshop Item (UNSPECIFIED)
Schools: Schools > School of Computing, Science and Engineering
Journal or Publication Title: International SAMPE Technical Conference
Publisher: Society for the Advancement of Material and Process Engineering
Depositing User: Dr Ganapathi Ammasai Sengodan
Date Deposited: 30 Sep 2022 11:42
Last Modified: 30 Sep 2022 11:42
URI: https://usir.salford.ac.uk/id/eprint/64986

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