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Frequently Asked Questions (December 4, 2003)

What is the best cord type for my application? The 3SX and 3X2 cords are the defacto standard cord types. They are the most economical and most readily available and are the best place to start. Use the 3SX for flatter and slightly curved projects and the 3x2 for more complex shapes and tension dominated projects. The 12X is the most flexible and pliable, allowing you to drape it over surfaces. The 3S is optimized for compression and is a better choice in these applications, but is only available in high density.

How do I cut the Hardwire tapes? If you are going to do any type of production you MUST have a set of heavy duty electric metal shears. See the section under Using Hardwire that deals with cutting tapes.

What are the issues with cutting Hardwire laminates? Laminates with Hardwire are VERY difficult to cut with traditional tools. Always kit cut holes prior to laying up the laminate and NEVER leave tag edges that need to be trimmed with Hardwire in the laminate. Make sure any edges to be trimmed do not have Hardwire in the laminate. Water jet cuts the laminates very well. Core drills work well for drilling.

Isn't the metal Hardwire tape heavy? Although the Hardwire tape appears heavier than glass fabrics, if you design a part to equal stiffness and keep the outside geometry the same (can't beat mother nature, T is T) you will use approximately 70% fewer layers resulting in a part that is up to 20% lighter. Since your layer is much thinner (similar to carbon) your core can become thicker to provide the additional stiffness (t3). Additional savings are realized with 70% less resin, less labor to layup, increased mold turnover,...

What about corrosion in the laminate? As long as the Hardwire materials are embedded into the laminate and fully covered, corrosion should not be an issue. Wick testing has shown that when properly protected the steel fibers will not wick water into the laminate. The AO coatings in addition to providing increased adhesion also provide corrosion resistance. Always confirm this with your own testing.

Can I use my existing resin systems? Absolutely. Hardwire was developed with this issue in mind. The lower density tapes allow for very high viscosity resins, including cement based resins, to be used while the higher density fabrics continue to work well with medium viscosity resins. We have infused parts with the high density tapes (23wpi) with resin viscosity's over 800cps. We recommend 250cps resin viscosity's. The AO coatings give great adhesion properties in polyesters, vinylesters, and epoxies.

Is it possible to weld Hardwire? Yes. Hardwire laminates have up to 40% steel fiber in infused laminates (higher volumes available under pressure) Mig and Tig welders have been used to actually weld the laminate to solid steel surfaces.

Is Hardwire good for attachment points? Due to the metallic nature of the Hardwire material, it makes a great attachment point reinforcement material. Anywhere your laminate supports other structures, especially when those other structures bear load or interact with steel, are excellent spots for Hardwire to be located. Try to kit cut all fittings prior to lamination.

Why is Hardwire good for tooling? Fiberglass is an insulator ... steel is a conductor. Composite tools are great in that complex molds can be created for minimal cost. The problem is that they do not do two things well ... spread the heat on the surface of the part during curing (exotherm) which results in hot spots and poor finishes, and the ability to get heat into the part evenly via heated tools. Hardwire tools, particularly with the Hardwire "M" copper mat at the surface, are very thermally conductive and correct these issues.

What about the difference in CTE (Coefficient of Thermal Expansion) between glass and Hardwire? CTE is a very real issue when using carbon based products and glass. Carbon has a CTE of virtually 0 while a glass/epoxy laminate has a CTE of about 8E-6 (per 1 deg C) creating a difference of about 8E-6. Aluminum has a CTE of about 22E-6 which creates a 22E-6 difference with carbon. However, the high carbon steel utilized in Hardwire has a CTE of approximately 10.5E-6, creating a difference of about 2.5E-6 to 3.5E-6 (resin dependent), which is similar enough with glass to prevent warping of the laminate. Always perform your own in-house tests prior to scaling the laminate into production.

Is Hardwire good in ballistic applications? There have been some very positive results utilizing Hardwire in ballistic applications. Ballistics is a science in which each "expert" can have widely differing views on how to construct a ballistic panel. Hardwire has worked well in some of these applications, although no one will tell you exactly how they used the material.