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Transportation Industry Marine Composites A torsionally stiff, lightweight monocoque chassis was designed and fabricated in 1986 by the Vehicle Research Institute at Western Washington University, Bellingham, WA. Called the Viking VIII, this high performance, low cost sports car utilizes composite materials throughout and weighs only 1,420 pounds. Fiberglass, Kevlarfi and carbon fiber were used with vinyl ester resin, epoxy adhesive and aluminum honeycomb core in various sandwich configurations. Final detailed test results were not available in the literature, however, most of the performance goals were met with the model. [1-57] Safety Devices Honeycomb structures can absorb a lot of mechanical energy without residual rebound and are particularly effective for cushioning air dropped supplies or instrument packages in missiles, providing earthquake damage restraints for above ground pipelines, orFigure 1-42 Composite El- protecting people in rapid transit vehicles. A life-saving liptic Spring [ASM Engineers’ cushioning device called the Truck Mounted Crash Guide to Composite Materials] Cushion (TMCC) has been used by the California Department of Motor Transportation. The TMCC has proven effective in preventing injury to, and saving the lives of, highway workers and motorists. The TMCC is mounted to slow moving or stopped transportation department maintenance and construction vehicles. In case of an accident, after an initial threshold stress (that can be eliminated by prestressing the honeycomb core) at which compressive failure begins, the core carries the crushing load at a controlled, near linear rate until it is completely dissipated without bouncing the impacting car or truck into a work crew or oncoming traffic. Electric Cars The promise of pollution reduction in the nation’s cities through the utilization of electric vehicles (EV) relies in a large part in getting the vehicle weight down. In 1992, GM produced an all-composite electric car called the Ultralite. The body structure was hand laid up carbon/epoxy built by Scaled Composites and weighed half (420 pounds) of what a similar aluminum frame would weigh with twice the stiffness. Although material costs and manufacturing methods for this project were not realistic, it did prove the value of parts consolidation, weight reduction, corrosion resistance and styling latitude. [1-58] Solectria has recently produced an all-composite sedan called the Sunrise built under Advanced Research Projects Agency (ARPA) funding. The company holds the EV range record of 238 miles on a single charge and has teamed up with composites manufacturer TPI and Dow- United Technologies (a Sikorski Aircraft spinnoff) for this effort. Dow-UT makes RTM parts for the aerospace industry and produces carbon composite parts for the Dodge Viper. [1-59] 45PDF Image | Marine Componsites
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