Composite Cycle Frame Manufacturing Methods - Research Paper Example

Composite Cycle Frame Manufacturing Methods Composite Cycle Frame Manufacturing Methods Introduction This is a method that offers the most durable materials for manufacturing bicycles. The name composite in this case shows that it has several materials. The materials that make up the bicycles are resin and carbon fibres. The carbon fibres are man-made and they produce quality bicycles unlike isotropic materials. There are mainly two methods in the manufacturing process of bicycles under this technique. The first method is the Resin transfer. It is used in lugged construction in which tubes made of carbon are bonded. The bonding is done to internal lugs or external then held together using glue. The second method is the closed mould which uses a bag and foam core. This method is commonly used to manufacture frames and monocoque frames. This paper analyses the process of manufacturing bicycles using the carbon fibre in two parts. This includes the time that carbon fibre takes to corrode during the process. This part looks at the process of manufacturing a bicycle using the methods available under the use of composite. The second part is the options available for corrosion resistance for the components used in the method. It is important to protect frames of these bicycles against corrosion which constitutes much of damages caused con them. Corrosion of carbon fibre Carbon fiber, which is also known as graphite fiber or even carbon graphite, is a material that is composed of fibers nearly a diameter of 5–10 μm and mainly consists of carbon atoms. They are joined in crystals that align themselves parallel to the fiber’s long axis. The alignment of the crystals provides the fiber with high strength to volume ratio, this renders it strong for its size. Many carbon fibers are brought together or joined to make a tow; this can be used by itself or even make a fabric (Campbell, 2003, p.36). The carbon fibers’ characteristics, like high solidity, low density, high tensile strength, high tolerance to temperature, high chemical opposition, and low thermal expansion greatly makes them to be largely used in military, aerospace, motorsports as well as civil engineering, also in some other competition sports. The carbon fibers are slightly expensive in comparison with some other fibers like plastic fibers and glass fibers. They are normally mixed with some other materials to come up with a composite. When they are mixed with a plastic resin and then molded, we find that the result is carbon fiber reinforced plastic; this is commonly known as carbon fiber and has a strength-to-weight ratio that is very high, which is very rigid even though fairly brittle. In addition, the carbon fibers consist of some other materials like graphite, which makes carbon-carbon composites that have heat tolerance that is very high (Kosher, 2011, p.45). Even though it has a relatively high resistance to corrosion, carbon fiber is largely used in several industries for different purposes. The metallic corrosion’s cost to the total economy should be quantified in several Euros or dollars per year. Since they present the largest used single class of alloys; that is both in terms of the total cost and tonnage, we find that it is very easy to comprehend or understand the fact that the corrosion of carbon fibers is a problem of huge practical significance. This is actually the fundamental reason for the presence of whole industries that are dedicated to the provision of protective systems for steel and irons. The options available for corrosion resistance for the components Corrosion is a reaction that takes place due to chemical reactions that affects surfaces and causes damage. The chemical reactions are as a result of reaction of moisture and the surface. It causes damage to such surfaces; hence, the need to use protective measures to prevent corrosion. The first step in doing this is to identify the various types of carrion that can happen depending on the materials and factors that cause this corrosion in the materials. It is important to consult an expert in this area after identifying the materials to be protected from corrosion. Such advice can be got from the manufacturer of the product or from a producer of lubricants. Non- Distraction Testing in controlling corrosion There are various tests conducted to test how reliable the corrosion preventive methods are. These methods are, however, not very effective because they do not last for a long period of time. The Non- Distraction Testing method is effective because it is a long-term method. There are various methods under this specific test. This method prevents the parts of the bicycle from failing due to corrosion. Other types of the NDT include the gas corrosion test, ultrasonic and chlorine test among others. However, the gas corrosion test is more reliable than the rest. In this test, parts of the bicycle are arranged in the set chamber. Some parts are arranged when the concentration is high or when the temperature is high. This depends on the material that the part is made of. It is important to first determine the type of material before settling for one of the methods above. This is because the material is very sensitive to some gases like chlorine oxide or ammonia. The gold coating sample differs from other materials like copper and silver. Graphs are used to show the relation between the concentration of the gases and time. It analyzes the difference during the production of the protective coating. Using protective coatings can also be a method of corrosion resistance for the components in the bicycle. There are various materials that can be used to protect carbon fibre components bicycles. Such materials may include zinc thermal spray. It is sprayed on the bicycle so that it gains the protection against corrosion by protecting the surface. An example of a protective coating that is very effective is the chromium and nickel coating. They are very effective in offering the protection against corrosion in bicycles with these components. They protect against environments that are highly acidic and salty. Therefore, it becomes safe to use these bicycles in such environments without the fear of corrosion damaging them. The carbon fibers are by their nature of little alloy content, often below two percent by weight for the whole or entire additions. These additions levels unfortunately do not, in general, bring about any considerable or meaningful changes in corrosion behavior generally. The carbon fibers do not deteriorate, or in other words are resistant to corrosion, or might take too long to be corroded. One likely exception to this assertion is weathering steels, chromium, small additions of copper and phosphorus, which produce substantial decrease in the rate of corrosion in some environments or surroundings. Since corrosion is such a composite matter, it is very important to try to put various types into categories or classifications. This is normally done on the basis of environment. Atmospheres are normally categorized as being machine, rural or even industrial in nature. However, two absolutely rural surroundings can differ extremely in average annual temperature and mean temperature and probably acid rain, can make some extrapolations from the past behavior less consistent. For instance, the carbon steel’s corrosion in the atmosphere and also in several aqueous atmospheres is best implicit or understood from a film pattern and brake down position (Mobasher, 2011, p.96). In addition, inevitable or unavoidable fact that in the presence of water and oxygen, iron is thermodynamically unsteady in regards to its oxides. Since atmospheric corrosion is considered electrolytic process, we find that the presence of an electrolyte is paramount. This should not be regarded or imply that the surface of steel should be awash in the water; whereby a very thin adsorbed water film is all that is important. During the real exposure, it spends some part or section of the time awash with water due to splashing or rain and a part of the time taken with a thin adsorbed film of water. The fraction of time that is spent covered with the thin film water is dependant somehow strongly on the relative humidity at the site of the exposure. However, this fact has made several scientists on corrosion to examine the effect of the period of wetness on the rate of corrosion (Mobasher, 2011, p.97). The rusting of iron is dependent on the relative humidity together with the period of exposure in the atmosphere that consists of 0.01 percent SO2. The rise in the rate of corrosion that is produced by the SO2 addition is imperative. The nitrogen’s oxides in the atmosphere exhibit an increasing effect on the steel’s corrosion. Any gaseous constituent of atmosphere that is capable of powerful electrolytic action should be assumed as being in a position of raising the rate of corrosion of steel (Raj, 2002, p.36). The options available for corrosion resistance for the components Corrosion is a reaction that takes place due to chemical reactions that affects surfaces and causes damage. The chemical reactions are as a result of reaction of moisture and the surface. It causes damage to such surfaces; hence, the need to use protective measures to prevent corrosion. The first step in doing this is to identify the various types of carrion that can happen depending on the materials and factors that cause this corrosion in the materials. It is important to consult an expert in this area after identifying the materials to be protected from corrosion. Such advice can be got from the manufacturer of the product or from a producer of lubricants. It is then important to look at the service conditions in selecting options for corrosion resistance for the above components. Performance requirements are one of these service conditions. The common criteria under this is looking at the amount of load that the bicycle supports, the type of rotation it uses and the speed used. It is also important to consider the type of lubrication needed. It is vital to analyse the contaminants that the bicycle is exposed to during its operations. For instance, it is obvious that exposure to moisture and water will cause corrosion. Therefore, if the area where the bicycle is to be used is prone to these hazards, then it is important that measures are taken against that (Schweitzer, 2006, p.77). The first method in preventing corrosion is by the use of lubricants. It is good to note that not all lubricants can be used for this purpose because some are not as effective as others. Therefore, it is essential that one consults with experts on the best type of lubricant to use on the bicycle. Some lubricants can only be used in areas where the corrosive environment is mild and vice versa. Some examples of lubricants to use in a bicycle manufactured by these carbon fibre components include grease. Over-lubricating is highly discouraged in carbon fibre bicycles because it causes overheating in the bearings which in turns causes wear and tear. This means that the lifespan of the bicycle is reduced by some percentage (Schweitzer, 2006, p.57). The use of seals is another method to be used in carbon fibre component bicycles. They are used in keeping particles of the bicycle out of bearing. However, the seal materials do not offer maximum protection against liquids and gases. This means that this option is not among the best because it is not that much effective in comparison to the first option. An example of a seal material is rubber and nitrile. Phosphates of zinc and manganese offer excellent protection against corrosion; hence, making this method an effective option for these bicycles. Black oil oxide is also another option under this method. However, it is only applicable for short period s of time. This means that it cannot protect the surface for a long period of time; hence, not such an effective option for long period of time. With the use of black oil oxide, surfaces have to be checked frequently to avoid corrosion. Zinc thermal spray on the other hand offers protection for a long period of time. It makes it an effective method for preventing corrosion. Most of these coatings and plating used end up separating themselves from the main surface of the bicycle or peeling. Research shows that highly density chromium like Endurakote process protect surfaces from corrosion by a large percentage; hence, making it an effective option.440C stainless steel is another type of coating that reduces corrosion by a large percentage on carbon fibre components. These methods apply on bearing rings of bicycles with small diameters. In environments that are highly prone to corrosion such options like use of stainless steel. This option is very effective though it is an expensive method. The process of using stainless steel consumes much time because it is a technical method. However, it gives an assurance of protection for a long period of time and ensures effectiveness (Worland, 2003, p.24). Conclusion Corrosion constitutes the larger percentage of damage in bicycles made from carbon fibre components. This is so depending on the environment that the bicycle is being used. Corrosion affects the performance of bicycles made from these components and their level of productivity is made low. It also makes the cost of operation very expensive because of servicing it after damage caused by corrosion. It is for this reason that protective measures against corrosion are taken both by the manufacturer and by the users or consumers. Manufacturers should use material that is not highly prone to corrosion and also add coatings that are effective. Consumers also have the responsibility of using lubricants on such bicycles like grease. References Campbell, F. C 2003, Manufacturing processes for advanced composites, Elsevier. Kosher, R 2011, DeGarmo’s materials and processes in manufacturing, John Wiley & Sons. Mobasher, B 2011, Fibre and fabric reinforced composites: manufacturing, analysis and designs, CRC Press. Raj, B 2002, Corrosion of austenitic stainless steel: mechanism, mitigation and monitoring, Woodhead Publishing. Schweitzer, P 2006, Paint and coatings: applications and corrosion resistance, Taylor & Francis Group. Worland, S 2003, The mountain bike book, MBI Publishing Company. Read More