Documente Academic
Documente Profesional
Documente Cultură
111
Advanced
Composite
Materials
Chapter
7
Eye protec=on
Skin
protec=on
Use
gloves
and
protec=ve
clothing
! Wash
hands
aIer
handling
material
!
Wing
Horizontal
Stabilizer
Fuselage
AircraI Axes
Lateral
Axis
!
AircraI Axes
Longitudinal
Axis
!
Ver=cal
Axis
!
AircraI Structures
A
true
monocoque
structure
has
bulkheads
and
formers
to
give
the
structure
its
shape,
but
all
of
the
ight
loads
are
carried
in
the
thin
sheet
metal
skin.
AircraI Structures
A
semimonocoque
structure
carries
the
ight
loads
in
its
outer
skin,
but
this
thin
skin
is
backed
up
with
stringers
that
extend
across
the
formers.
AircraI Structures
The reinforced shell is the most generally used type of construc=on for modern all-metal aircraI.
Stress
Video
Diamond Construc=on
Composite Structures
Advantages:
Complex
shapes
! Labor
savings
! Moistures
resistant
! Weight?
!
Disadvantages:
!
Complex
repairs
The
method
of
repair
will
vary
from
aircraI
to
aircraI
Separa=on
of
layers
Electric
shielding
layer
can
be
an
issue
Composite Structures
Components:
!
Fiber/reinforcing
material
The
real
strength
Matrix (glue)
Recipe
or
formula:
!
Fiber
Type
Orienta=on
&
weave
Layering
Placement
Matrix
Curing
process
Fiber Deni=ons
Unidirec=onal Tape
Bidirec=onal Fabric
Fabric Layout
Warp Clock
Fiberglass
Fiber
Low
cost
!
S-glass
High
tensile
strength
and
s=ness
Aramid
ber
Kevlar
! High
tensile
strength
and
exible
! Yellow
!
Reinforcing Material
Light
and
s=
! Used
to
add
rigidity
to
structures
! Electrically
conduc=ve
!
Very
expensive
! Black
!
Reinforcing Material
Fiber Orienta=on
Matrix Materials
Glue
Only
job
is
to
link
the
bers
Minimize
the
amount
to
reduce
weight
!
Follow
direc=ons
Only
way
to
test
is
to
make
a
test
piece
Polyester
!
Matrix Materials
Two
part
Resin
Catalyst/ac=vator
!
!
Can
be
thinned
! Easy
to
color
! Surface
must
be
sealed
before
it
will
fully
cure
!
Matrix Materials
Epoxy
!
Two
part
Resin
Catalyst/hardener
!
Matrix Materials
Core Material
Balsawood
!
Core Material
Foams
!
Styrofoam
(polystyrene)
Cut
with
hot
wire
Can
not
be
used
with
polyester
resin
Urethane
Fuel
proof
Cant
be
cut
with
hot
wire
Can
be
used
with
epoxy
or
polyester
resin
Honeycomb
Core Material
Ribbon Direc=on
Filler Material
Thickens
matrix
Microspheres
or
micro-balloons
Tiny
hollow
glass
balls
! Very
light
!
Adds strength
Talc
Cab-o-sil
-
silicon
dioxide
Manufacturing Methods
Usual
moldless
! Appling
reinforcement
material
and
matrix
by
hand
!
Matched
Dies
!
Vacuum
Bag
A
vacuum
bag
is
used
to
create
a
vacuum
around
a
component
! Atmospheric
pressure
forces
wet
structures
into
mold
! Vacuum
assists
in
removing
excess
matrix
!
Manufacturing Methods
Matched Dies
Heated matched dies are used for making a large number of iden=cal parts.
Vacuum Bag
A
vacuum
bag
may
be
used
to
apply
the
pressure
to
a
composite
lay-up
to
ensure
that
it
takes
the
shape
of
the
female
die
and
to
ensure
that
all
of
the
individual
bers
are
completely
encapsulated.
Filament Winding
When the maximum strength is required, the part may be lament-wound and cured in an autoclave.
Problems:
Inspec=on
Cracks
! Delamina=on
Separa=on
of
composite
layers
! Matrix
void
detec=on
Usually
aIer
repairs
or
manufacturing
! Trapped
water
!
Methods:
!
Inspec=on
Methods:
Inspec=on
Ultrasonic
inspec=on
! Radiographic
(X-ray)
! Backligh=ng
!
Repair
Non-structural
repair
e.g.
cracked
wheel
pants
! Stop
drill
the
crack
! Apply
the
repair
to
the
inside
!
Test rst
Repair
Typical dimensions for a room-temperature repair to the face plies of a honeycomb core composite panel.
Repair
Repair
Repair
Plas=cs
ThermoseAng
Set
by
heat
once,
reapplica=on
of
heat
will
destroy
it
Thermoplas=c
Can
be
soIened
by
heat,
and
when
they
are
cooled
they
will
regain
their
original
hardness
and
rigidity
Not
damaged
by
repeated
hea=ng
and
cooling,
so
long
as
they
are
not
overheated.
Thermoplas=cs
Acrylics
Modern
type
! Plexiglas,
Lucite
and
Perspex
!
Acetate
Older
type
! Yellows
and
gets
brille
with
age
!
Thermoplas=cs
Storage
Transparent Plas=cs
Leave
paper
on
! Store
ver=cally
at
a
10
=lt
! If
stored
horizontally,
insure
not
dirt
is
trapped
!
CuAng
Cut
large
and
sand
to
size
! Dont
overheat
or
melt
!
Drill
bits
!
Transparent Plas=cs
Steps:
Cleaning
!
Transparent Plas=cs
Transparent Plas=cs
Installa=on
Crazing
Transparent Plas=cs
Delamina=on
!
Must be replaced
Patches
Patches
Video
Scratches