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Carbon fiber intake plenum
Carbon fiber intake plenum
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Carbon fiber intake plenum
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Elias_GR
Elias_GR
posted 9 Years Ago
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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.
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Hanaldo
Hanaldo
posted 8 Years Ago
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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.
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8 Years Ago by
Hanaldo
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Carbon fiber intake plenum
Elias_GR
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9 Years Ago
I would probably build it a fair bit stronger than that to be honest, and probably ditch the Kevlar....
Hanaldo
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9 Years Ago
Thanks Hanaldo! I'm aiming for 2-2.5mm for total safety to be exact. Would it be better if i used...
Elias_GR
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9 Years Ago
For 2-2.5mm you will want 4 or 5 layers of 450 with a layer of 200 on either side. Alternatively 3-4...
Hanaldo
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9 Years Ago
I made a carbon plenum for my noble over the past 8 months... not bonded it together but its strong...
andygtt
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8 Years Ago
I would echo above, I didn't use any kevlar..... Id also make it in PrePreg as I wanted to cure it...
andygtt
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8 Years Ago
Thanks a lot for the replies! You've done a really nice work on the intake plenum there Andy! I...
Elias_GR
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8 Years Ago
I'm in the same boat I want to create a plenum fairly soon but I don't have access to a prepreg...
davro
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8 Years Ago
I was thinking exactly the same thing yesterday, about the heat reflective materials. The one...
Elias_GR
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8 Years Ago
Bit of an older post, however I could use some suggestions in materials for heat reflection. Suggestions appreciated.
Jadleybray
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8 Years Ago
You really should be ok, you may just suffer a bit of print-through. I've made plenty of engine bay...
Hanaldo
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8 Years Ago
Hanaldo thanks for the reply! The resin I'm going to use has 123C Tg, so the only thing "I'm most...
Elias_GR
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8 Years Ago
I built myself an oven purely so I could make the plenum in prepreg, it was my first ever part in...
andygtt
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8 Years Ago
So after quiet a while I found some time to continue the project! Yesterday i got the plugs from the CNC and I've already started to seal the wood so I can produce a mold. I'll get back with plenty o...
Elias_GR
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7 Years Ago
Good stuff mate, man CNC's make this game too easy! Haha. Interesting plenum design, I hadn't realised from your drawing it was such a tight area at the back. what sort of engine is it for?
Hanaldo
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7 Years Ago
Thanks Hanaldo! CNC's are really an enormous help! The intake will be put in a small Nissan engine, for some tests and the we will upscale it for (hopefully) something better. Also if anyone has...
Elias_GR
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7 Years Ago
Interesting... CA, SR? Or something less mainstream? The build thread for my oven is here http://www.talkcomposites.com/21047/MDF-Curing-Oven?PageIndex=1 Still working like a charm, and I'm...
Hanaldo
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7 Years Ago
Hanaldo this will be tested on my ''lab rat'' which is a GA series motor that I've boosted a couple of years ago. Very helpful thread for the oven! Thanks! A bit more progress now. I sealed the MDF...
Elias_GR
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7 Years Ago
Nice project, I am waiting for more photos. 1.5-2 mm will be quite enought for the wall thickness.
ArturK
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7 Years Ago
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