Unit R014 - Engineering Manufacture - Topic Area 2 - Retrieval E

Engineering Composites

From the products below which is likely to be manufactured from a composite?

• 
• 
• 
• 

Answer explanation

Spoilers and other body panels on performance vehicles often use composites such as carbon fiber.

Carbon fiber brings the benefits of: high strength, formability into complex shapes and very low overall weight.

Engineering Composites

The definition of a composite is a mixture of two or more elements where at least one is a metal

• True

• False

Answer explanation

A composite material is a combination of two materials with different physical and chemical properties. When they are combined they create a material which is specialised to do a certain job, for instance to become stronger, lighter or resistant to electricity. They can also improve strength and stiffness.

With an alloy it is difficult to recognise the different alloying elements as they chemically join together.

With composites the materials used do not undergo chemical change and remain separate.

Engineering Composites

GRP is a composite used widely in engineering. What is its full name?

Glass ​ (a)   ​ (b)  

• Reinforced
• Plastic
• Reimagined
• Polymer
• Parts
• Rendered
• Product

Engineering Composites

GRP and fiberglass are phrases often used interchangeably for the same material. Put the basic steps in order for the manufacture of GRP products.

• Product removed from mould/template

• Resin is added to the mould or around the template.

• Fibers are woven.

• Fibers are placed into the mould or around the template.

• Part is allowed to dry and cure.

Engineering Composites

GRP (fiberglass) is widely used in the engineering sector but why?

• High strength to weigh ratio.

• Electrically non conductive

• Easy to weld.

• Non-Corroding

• Little to no up-keep maintenance required

Engineering Composites

The GRP pultrusion process is shown on the image. Select where the raw fiber is stored ready for weaving.

Engineering Composites

CFRP is the formal abbreviation for what widely used material?

• Carbon fabricated retail plastics

• Carbon Fiber

• Chemically formed reinforced pewter

• Copper frayed reactive plastic

Engineering Composites

What is the full name for CFRP?

​ (a)   ​ (b)   ​ (c)   ​ (d)  

• Carbon
• Fibre
• Reinforced
• Polymer
• Copper
• Fiscal
• Rolled
• Paint

Engineering Composites

Select the part of this image where you would expect carbon fibre to have been used?

Engineering Composites

Carbon fiber has an excellent strength to (a)   ratio. It also benefits from excellent ​ (b)   resistance. Finally it has superior resistance to ​ (c)   expansion.

• weight
• chemical
• thermal
• lenght
• length
• height
• cold

Answer explanation

The early fully commercial aircrafts were 70% aluminum. At the time this material was, lightweight, strong and easy to work with hence it's use.

However modern aircraft available now, such as the Boeing 787 Dreamliner, only 20% of the structure is aluminium with the remaining being largely engineering composites such as carbon fibre.

Carbon fibre is obviously incredibly lightweight however it has another couple of key advantages over many metals. Carbon fibre avoids thermal expansion and contraction from extremes of temperature (a perfect property for the manufacture of aerospace components). It also suffers from very little fatigue wear meaning the material with have an increasingly long life cycle in comparison to many metals.