Use of Composites as alternative Materials in ship structures-Basem E. Tawfik-MSC Thesis-Alexandria University-Egypt

206 Pages·2017·15.26 MB·English

Use of Composites as

Alternative Materials
in Ship Structures

A thesis
Submitted to the Naval Architecture and Marine
Engineering Department
Faculty of Engineering – Alexandria University
in partial fulfillment of the requirements
for the degree of
Master of Science
in
Naval Architecture and Marine Engineering

by

Basem E. Tawfik

May 2017
Use of Composites as Alternative Materials in Ship
Structures

Presented by
Basem E. Tawfik

for the degree of

Master of Science

in
Naval Architecture and Marine Engineering

Examiners' Committee: Approved

Prof. Dr. Heba Wael Leheta ………………
Prof. Dr. Heba El Kelany ………………
Prof. Dr. Adel Abdelhalim Banawan ………………
Prof. Dr. Ahmed Mohamed Elhewy ………………

Vice Dean for Graduate Studies and Research
Advisors' Committee:

Prof. Dr. Heba Wael Leheta ……………
Prof. Dr. Tarek Elsayed .……………
Prof. Dr. Ahmed Mohamed Elhewy ……………
ACKNOWLEDGMENT
Before all I would like to thank “Allah” for his blessings for being able to finish this
research.
This research work was a tough yet Joyful experience in which I owe the inspiration
of the subject to Prof. Heba Wael Leheta and the encouragement of my advisors, Prof.
Ahmed Elhewy and Prof. Tarek Elsayed. For all that; kindly accept my sincere appreciation
and thanks.
On the other hand, I would like to express my deep great thanks and gratitude to my
beloved wife Sara, without her understanding, encouragement and support I wouldn’t have
been able to finish the thesis. At last, my parents deserve a particular note of thanks: your
kind and warm love, as always, served me well.

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TABLE OF CONTENTS
ACKNOWLEDGMENT ...................................................................................... i
TABLE OF CONTENTS .................................................................................... ii
LIST OF FIGURES .......................................................................................... vi
LIST OF TABLES ............................................................................................ xi
LIST OF ABBREVIATIONS ............................................................................ xii
NOMENCLATURE ......................................................................................... xiv
ABSTRACT .................................................................................................... xvi
CHAPTER 1 :INTRODUCTION ........................................................................ 1
CHAPTER 2 :OVERVIEW OF COMPOSITE MATERIALS ............................... 3
2.1.BACKGROUND ....................................................................................................... 3
2.2.DEFINITION OF COMPOSITES ............................................................................. 4
2.3.TYPES AND CLASSIFICATION OF COMPOSITE MATERIALS ...................... 5
2.3.1.Particle-Reinforced Composites ..................................................................... 5
2.3.2.Fiber-Reinforced Composites ......................................................................... 7
2.3.3.Structural Composites: .................................................................................... 9
2.3.4.Hybrid Composites ....................................................................................... 12
2.3.5.Advanced Composites .................................................................................. 13
2.4.CONSTITUENT MATERIALS .............................................................................. 14
2.4.1.Reinforcement ............................................................................................... 14
2.4.1.1.Reinforcement Construction ...................................................................... 14
2.4.1.2.Fiber Types ................................................................................................ 15
2.4.1.2.1.Glass Fibers ............................................................................................ 16
2.4.1.2.2.Carbon and Graphite Fibers .................................................................. 17
2.4.1.2.3.Aramid Fibers ......................................................................................... 17
2.4.1.2.4.Extended chain polyethylene fibers ........................................................ 18
2.4.2.Matrix ............................................................................................................ 23
2.4.2.1.Thermosets ................................................................................................. 25
2.4.2.1.1.Epoxies .................................................................................................... 25
2.4.2.1.2.Bismaleimides ......................................................................................... 26
2.4.2.1.3.Polyimides ............................................................................................... 26
2.4.2.1.4.Polyesters and vinyl esters ...................................................................... 26
2.4.2.1.5.Cyanate esters ......................................................................................... 27
2.4.2.1.6.Phenolics ................................................................................................. 27
2.4.2.2.Thermoplastics ........................................................................................... 27
2.4.3.Core Materials ............................................................................................... 28
2.4.3.1.Balsa .......................................................................................................... 29
2.4.3.2.ThermosetFoams ........................................................................................ 30
2.4.3.3.SyntacticFoams .......................................................................................... 30
2.4.3.4.Cross Linked PVC Foams .......................................................................... 31
2.4.3.5.Linear PVC Foam ...................................................................................... 31
2.4.3.6.Honeycomb ................................................................................................ 32
2.4.3.7.PMI Foam .................................................................................................. 32
2.4.3.8.FRP Planking ............................................................................................. 32
2.4.3.9.Plywood ..................................................................................................... 33
2.5.ADVANTAGES AND DISADVANTAGES OF COMPOSITE MATERIALS .... 33
2.5.1.Strength and Stiffness Advantages ............................................................... 34
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2.5.2.Cost Advantages ........................................................................................... 37
2.5.3.Weight Advantages ....................................................................................... 39
2.5.4.Disadvantages ............................................................................................... 40
2.6.MARKET DEMAND FOR COMPOSITE MATERIALS ...................................... 41
2.7.PRODUCTION (MANUFACTURING) METHODS ............................................. 42
2.7.1.Hand Lay-Up ................................................................................................ 43
2.7.2.Spray-Up ....................................................................................................... 44
2.7.3.Filament Winding ......................................................................................... 45
2.7.4.Pultrusion ...................................................................................................... 46
2.7.5.Vacuum Bag Molding ................................................................................... 47
2.7.6.SCRIMP ........................................................................................................ 48
2.7.7.Autoclave Molding ....................................................................................... 49
2.7.8.Resin Transfer Molding ................................................................................ 50
2.7.9.Compression Molding ................................................................................... 51
CHAPTER 3 : MECHANICS OF COMPOSITE MATERIALS ........................... 53
3.1.INTRODUCTION ................................................................................................... 53
3.1.1.Mechanical Response ................................................................................... 55
3.1.2.Coordinate System ........................................................................................ 56
3.2.MACROMECHANICAL BEHAVIOR OF A LAMINA ....................................... 59
3.2.1.Stress–Strain Relationships ........................................................................... 59
3.2.2.Engineering Constants for Orthotropic Materials ......................................... 62
3.2.3.Strength Criteria for an Orthotropic Lamina ................................................ 64
3.2.3.1.“Maximum Stress” Failure Criterion ........................................................ 65
3.2.3.2.“Maximum Strain” Failure Criterion ....................................................... 66
3.2.3.3.Quadratic Failure Criterion ...................................................................... 66
3.3.MICROMECHANICAL BEHAVIOR OF A LAMINA ......................................... 67
3.3.1.Elastic Properties .......................................................................................... 68
3.3.2.Lamina Strength ............................................................................................ 69
3.4.MECHANICAL BEHAVIOR OF A LAMINATE ................................................. 70
3.4.1.Classical Lamination Theory ........................................................................ 71
3.4.1.1.Lamina Stress-Strain Behavior .................................................................. 71
3.4.1.2.Strain and Stress Variation in a Laminate ................................................. 72
3.4.1.3.Resultant Laminate Forces and Moments ................................................. 74
3.4.2.Strength of Laminates ................................................................................... 77
3.4.3.Computer Laminate Analysis ....................................................................... 79
3.4.4.Carpet Plots ................................................................................................... 80
CHAPTER 4 : COMPOSITES APPLICATIONS IN SHIP STRUCTURES .......... 83
4.1.INTRODUCTION ................................................................................................... 83
4.2.MATERIALS AND PRODUCTION METHODS .................................................. 85
4.3.COMPLETE COMPOSITE HULLS ....................................................................... 89
4.3.1.Recreational Industry .................................................................................... 89
4.3.1.1.Power racing boats .................................................................................... 89
4.3.1.2.Sail racing boats ........................................................................................ 92
4.3.1.2.1.The Volvo Ocean Race ............................................................................ 92
4.3.1.2.2.Volvo Ocean 65 Race Boat ..................................................................... 93
4.3.1.3.Pleasure yachts .......................................................................................... 96
4.3.1.3.1.Evviva ...................................................................................................... 96
4.3.1.3.2.SuperSport .............................................................................................. 97
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4.3.1.3.3.(M5) Mirabella V .................................................................................... 99
4.3.1.3.4.Tûranor Solar Yacht Hull ..................................................................... 100
4.3.2.Commercial Industry .................................................................................. 102
4.3.2.1.SSC study ................................................................................................. 103
4.3.2.2.Passenger ferries ..................................................................................... 103
4.3.2.2.1.Composite Ferries for USA Market ...................................................... 104
4.3.2.2.2.Composite Ferry vs. Aluminum Ferry .................................................. 105
4.3.2.3.Wave star Energy system ......................................................................... 106
4.3.2.4.FRP lifeboat ............................................................................................. 108
4.3.3.Naval Vessels .............................................................................................. 108
4.3.3.1.Patrol boats .............................................................................................. 110
4.3.3.2.Mine counter measure vessels (MCMV) .................................................. 111
4.3.3.2.1.Landsort / Koster Class MCMV ............................................................ 112
4.3.3.3.Corvettes .................................................................................................. 114
4.3.3.3.1.Visby class Corvettes ............................................................................ 114
4.3.3.3.1.1.Materials ............................................................................................ 115
4.3.3.3.1.2.Construction technique ...................................................................... 116
4.4.COMPOSITE PARTS ........................................................................................... 117
4.4.1.Superstructures ............................................................................................ 118
4.4.1.1.DDG-1000 Zumwalt class ....................................................................... 118
4.4.1.2.Passenger ship’s Superstructure ............................................................. 122
4.4.1.3.Superstructure of a RoRo vessel .............................................................. 126
4.4.2.Hatch Covers ............................................................................................... 128
4.4.2.1.Oshima ECO-Ship 2020 ........................................................................... 128
4.4.2.2.M/V Nordic Oshima ................................................................................. 129
4.4.3.Propellers .................................................................................................... 129
4.4.3.1.Alkmaar-class mine hunter ...................................................................... 130
4.4.3.2.QinetiQ propeller ..................................................................................... 132
4.4.3.3.Nakashima Propeller ............................................................................... 133
4.4.4.Rudders ....................................................................................................... 135
4.4.4.1.Composite twisted Rudders ...................................................................... 135
4.4.5.Propulsion Shafts ........................................................................................ 137
4.4.5.1.Early trials ............................................................................................... 138
4.4.5.2.JIME Research ......................................................................................... 138
4.4.5.3.Expeditionary Fighting Vehicle power systems ....................................... 139
4.4.6.Advanced Enclosed Mast System ............................................................... 140
4.5.MARINE COMPOSITES ROADBLOCKS .......................................................... 143
CHAPTER 5 : CASE STUDY (MARINE HATCH COVERS FOR LARGE
VESSELS) ...................................................................................................... 144
5.1.INTRODUCTION ................................................................................................. 144
5.2.DESIGN KEYS .................................................................................................... 145
5.3.PARTICULARS OF SELECTED VESSEL ......................................................... 145
5.4.CALCULATION OF DESIGN LOADS ............................................................... 147
5.5.DESIGN OF STEEL HATCH COVERS .............................................................. 148
5.6.DESIGN OF COMPOSITE HATCH COVERS ................................................... 150
5.6.1.Work Flow .................................................................................................. 150
5.6.2.Modeling ..................................................................................................... 151
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5.6.3.Meshing and Setting the Boundary conditions in Ansys
Mechanical ........................................................................................................... 153
5.6.4.Selection of Composite Material ................................................................ 156
5.6.5.Material Setup and Laminate Orientation in ACP-Pre ............................... 157
5.6.6.Assigning Thicknesses to Structural Members ........................................... 159
5.6.7.Defining Failure Criteria in Ansys ACP-Post ............................................. 160
5.6.8.Calculation of Member’s Thickness ........................................................... 163
5.6.9.Analysis and Post Processing ..................................................................... 164
5.6.9.1.Strengthening Approach .......................................................................... 164
5.6.9.1.1.Composite cover design ........................................................................ 164
5.6.9.1.2.Analysis results and discussion ............................................................. 165
5.6.9.2.Weight Reduction Approach .................................................................... 167
5.6.9.2.1.Composite cover design ........................................................................ 167
5.6.9.2.2.Analysis of results and discussion ........................................................ 169
5.7.COST ANALYSIS ................................................................................................ 171
5.7.1.Manufacturing Cost .................................................................................... 171
5.7.1.1.Steel Hatch cover ..................................................................................... 171
5.7.1.2.Composite hatch cover ............................................................................. 172
5.7.2.Life Cycle Cost Analysis (LCCA) .............................................................. 172
5.8.SUMMARY .................................................................................................... 173
CHAPTER 6 :CONCLUSIONS AND SUGGESTIONS FOR FUTURE WORK .. 175
REFERENCES ............................................................................................... 177
ARABIC SUMMARY ..................................................................................... 186

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LIST OF FIGURES
Figure 2-1 Relationships between Classes of Engineering Materials Showing the Evolution
of Composites [Harris Bryan 1999] ..................................................................................... 5
Figure 2-2 Principal Composite Materials [Vinson et al. 2004] .......................................... 6
Figure 2-3 A Classification Scheme for the Various Composite Types [Callister 2001] .... 6
Figure 2-4 Various Types and Orientation of Fibrous Composites [Mallick 2008] ............ 8
Figure 2-5 A Laminate Made-up of Laminae with Different Fiber Orientations [Reddy
2004] .................................................................................................................................. 10
Figure 2-6 Schematic Diagram Showing the Construction of a Honeycomb Core Sandwich
Panel [Callister 2001] ........................................................................................................ 11
Figure 2-7 Efficiency of the Sandwich Structure [Campbell 2010] .................................. 11
Figure 2-8 A Cross Section of a High-Performance Snow Ski [Callister 2001] ............... 12
Figure 2-9 Some Fiber Construction Forms [Campbell 2010] .......................................... 15
Figure 2-10 Unidirectional and Woven Cloth Prepreg [Campbell 2010] .......................... 16
Figure 2-11 Tensile Stress–Strain Diagrams for Various Reinforcing Fibers [Mallick 2008]
........................................................................................................................................... 20
Figure 2-12 Specific Strength and Modulus of Some Commercially Important Fibers
[Campbell 2010] ................................................................................................................ 23
Figure 2-13 Comparison of Thermoset and Thermoplastic Polymer Structures [Campbell
2010] .................................................................................................................................. 24
Figure 2-14 Cost Versus Performance for Core Materials [Campbell 2010] .................... 28
Figure 2-15 Balsa Cell Geometry [Greene 1999] .............................................................. 29
Figure 2-16 Syntactic Core Construction [Campbell 2010] .............................................. 31
Figure 2-17 Translation from Constituent Properties to Lamina to Laminate Properties
[Jones 1999] ....................................................................................................................... 35
Figure 2-18 Strength and Stiffness of Composite Materials and Metals [Jones 1999] ..... 36
Figure 2-19 Life-Cycle Cost Elements [Jones 1999] ......................................................... 38
Figure 2-20 The Relative Importance of Metals, Polymers, Composites, and Ceramics as a
Function of Time. The Diagram is Schematic and describes neither Tonnage nor Value.
The Time Scale is Nonlinear [Gibson 1994] ..................................................................... 42
Figure 2-21 Comparison of Composite Manufacturing Techniques [Potter 1996] ........... 43
Figure 2-22 Schematic of the Hand Lay-up Process [Gurit 2013] .................................... 43
Figure 2-23 Schematic of the SPRAY-UP Process [Gurit 2013] ...................................... 44
Figure 2-24 Schematic of the Filament Winding Process [Gurit 2013] ............................ 45
Figure 2-25 Schematic of the Pultrusion Process [Callister 2001] .................................... 46
Figure 2-26 Schematic of the Vacuum Bag Molding Process [Gurit 2013] ...................... 47
Figure 2-27 Schematic of SCRIMP [Gurit 2013] .............................................................. 48
Figure 2-28 A schematic of Autoclave molding process [Gurit 2013] .............................. 49
Figure 2-29 A Schematic of Resin Transfer Molding Process [Gurit 2013] ..................... 50
Figure 2-30 Schematic of the Compression Molding Process [Mazumdar 2002] ............. 51
Figure 3-1 Material with Three Planes of Symmetry [Kollar eta al. 2003] ....................... 53
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Figure 3-2 The Levels of Analysis for a Structure Made of Laminated Composite [Kollar
eta al. 2003] ........................................................................................................................ 54
Figure 3-3 Mechanical Behavior of Various Materials [Jones 1999] ................................ 56
Figure 3-4 The Global x, y, z and Local x , x , x Coordinate Systems [Kollar eta al. 2003]
1 2 3
........................................................................................................................................... 56
Figure 3-5 The x, y, z and x , x , x Coordinate Systems and the Corresponding
1 2 3
Displacements [Kollar eta al. 2003] .................................................................................. 57
Figure 3-6 The Stresses in the Global x, y, z and the Local x , x , x Coordinate Systems
1 2 3
[Kollar eta al. 2003] ........................................................................................................... 57
Figure 3-7 Stresses on an Element [Jones 1999] ............................................................... 59
Figure 3-8 Typical Failure Modes of Composites [Kollar 2003] ...................................... 64
Figure 3-9 Load-Displacement Curve of a Composite Part [Kollar 2003] ........................ 65
Figure 3-10 Representative Volume Element Loaded in the 1-Direction [Jones 1999] .... 68
Figure 3-11 The Basic Questions of Laminate Analysis ................................................... 70
Figure 3-12 Geometry of Deformation in the x-z Plane [Jones 1999] .............................. 73
Figure 3-13 Hypothetical Variation of Strain and Stress through the Laminate Thickness
[Jones 1999] ....................................................................................................................... 74
Figure 3-14 In-Plane Forces on a Flat Laminate [Jones 1999] .......................................... 75
Figure 3-15 Moments on a Flat Laminate ......................................................................... 75
Figure 3-16 Geometry of an N-Layered Laminate [Jones 1999] ....................................... 76
Figure 3-17 Laminate Strength-Analysis Elements [Jones 1999] ..................................... 77
Figure 3-18 Analysis of Laminate Strength and Load-Deformation Behavior [Jones 1999]
........................................................................................................................................... 78
Figure 3-19 Carpet Plots for [0°, ±45°, 90°] Kevlar Epoxy Laminates [Gibson 1994] .... 81
Figure 4-1 Marine Industry Reinforcement Material Use [Greene 1999] ......................... 86
Figure 4-2 Marine Industry Reinforcement Style Use ....................................................... 87
Figure 4-3 Marine Industry Resin System Use .................................................................. 87
Figure 4-4 Marine Industry Core Material Use ................................................................. 88
Figure 4-5 Building Processes within the Marine Industry ............................................... 88
Figure 4-6 Dubai Grand Prix in 2012 [Class-1 2012] ....................................................... 90
Figure 4-7 Earthrace Power Boat [Greene 2013b] ............................................................ 91
Figure 4-8 The Route of the 2014-15 Volvo Ocean Race [Volvo Ocean Race 2016d] .... 92
Figure 4-9 Volvo Ocean 65 Race Boat During Manufacture by Vacuum Bagging Infusion
in Italy [Farr Yacht Design 2012] ...................................................................................... 93
Figure 4-10 A 3D Model of Volvo Ocean 65 Boat [Volvo Ocean Race 2016a] ............... 95
Figure 4-11 Volvo Ocean 65 Boat in Real Operation [Scuttlebutt 2013] ......................... 96
Figure 4-12 M/Y Evviva [Super yachts 2016b] ................................................................. 97
Figure 4-13 MY Supersport 48M [Morpheus London 2015] ............................................ 98
Figure 4-14 MY Supersport 72M [Palmer johnson 2016b] ............................................... 99
Figure 4-15 M5, Ex Mirabella V [Super yachts 2016c] .................................................. 100
Figure 4-16 MY Turanor PlanetSolar [Greene 2013b] .................................................... 101
Figure 4-17 Design Characteristics of Turanor Solar Yacht [Black 2011b] ................... 102
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