Carbon fiber intake plenum


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Elias_GR
Elias_GR
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Hello everyone! 

I'm planing on making an intake plenum from carbon fiber and kevlar. It is for a turbocharged car, so it needs to withstand some pressure!
The boost will be under 1 bar at the moment but I'm planning on testing the part on 3 bars at least, for reassurance.
The parts will be made from heat resistant Vinylester probably, if not Epoxy resin and vacuum infusion.

I'm planning on using 3 layers of 200gr 2X2 Twill Carbon fiber and 2 or 3 layers of hybrid 164gr Plain Carbon/Kevlar, alternatly in the layers.
By that, I mean, the first layer will be Carbon fiber, then Carbon/Kevlar, then Carbon fiber etc etc.

Will these layers and fabrics will be enough? Should I add anything or change any of the layers?

Here is the 3D model of the parts in assembly. 

http://www.talkcomposites.com/Uploads/Images/ebdd8fd4-90c6-48d1-b1f0-a5c4.JPG


http://www.talkcomposites.com/Uploads/Images/a0ec41ec-9a6e-4ba7-b162-d36f.JPG
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Hanaldo
Hanaldo
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You really should be ok, you may just suffer a bit of print-through. I've made plenty of engine bay parts (including plenums) using an infusion resin with a Tg of 90, and for the most part they haven't even printed too badly. Hell, I've made inner guards for a 1500hp twin-turbo Impala, where the inner guards sit 5mm away from the exhaust manifold. These would easily be exposed to over 350C. Yes, they are discoloured quite badly in the area they sit close to the manifold, but that is the worst of it. 



I mean I'm not necessarily recommending using a 90 Tg resin for a 350C application, rather just pointing out that your parts aren't going to melt and fall apart. What will happen is that if they are exposed to heat above their capabilities then the resin will soften a touch, which will certainly lead to print through. If the parts are under load and are unsupported, they may distort quite badly depending on their geometry and the degree of load etc. For example on something like a plenum, if you had a hose clamp on the inlet piping, this may distort the mouth of the plenum. Or if you had your intake piping bolted onto a throttle body, and this was unsupported weight that was 'hanging' off the front of the plenum, then this may distort the entire plenum. 

So things like that are what you will want to consider. Otherwise, if you are only going 15-20 degrees above their Tg, the worst you are likely to experience is a bit of discolouration and some print-through. 
Edited 8 Years Ago by Hanaldo
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