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INDUSTRY
Contents
Basics of Composites
Need of Composites
History of Composites in Aviation.
The Need to move towards Composites.
Some Common Composites.
Manufacturing Processes.
Role of Composites in Aviation Today.
A Special Focus on Boeing 787/777.
The Future of Composites.
Conclusions.
Basics of Composites
A composite is a physical mixture of two dissimilar materials
Many material properties are conflicting in nature, e.g. strength and ductility
hardness and fracture toughness
Ceramics are hard, brittle, high modulus, low fracture toughness, low
electrical and thermal conductivity and low specific gravity.
Boeing 707
Aluminium skin 2024-T3
2% glass fibre composites
Continued
Boeing 737 - 1967
40
30
25
20 19 18
15
10 7 10
8
2
0
1940 1950 1960 1970 1980 1990 2000 2010 2020
Helicopter Composite
Content
Attributes of Composites
Lighter. Comparison of Strength to Weight Ratio
Stronger.
Fatigue Resistant.
Easy Workability.
Fire Resistant.
Moisture Resistant.
Environment Friendly.
Easy Handling.
High Thermal Stability.
Quality Control.
Some of the Common
Composites
Fiberglass Reinforced Plastic
As the most common composite material,
fiberglass, made from glass fibers
embedded in a resin matrix, was first used
largely for boats and automobiles in the
1950s, notes the Centennial of Flight
Commission. It was also used during this
time in constructing the Boeing 707
passenger jet. In 2010, engineers still use
fiberglass in aircraft construction, such as
in building airplane wings.
FRP
Common Composites
Cont.
Carbon Fiber Reinforced Plastic
This composite, made from carbon atoms and an
epoxy matrix, has strong value because of its light
weight. According to "Carbon Fiber Composites,"
the U.S. space shuttle utilizes carbon fiber.
"Fundamentals of Composites Manufacturing"
further notes that this material provides high cost
benefits, with launching into space costing roughly
$10,000 for every pound as of 2008.
Carbon fiber also provides heat resistance and thus
is useful for space vehicles and military aircraft.
Much of the fuselage of the new Boeing 787
Dreamliner and Airbus A350 XWB will be
composed of CFRP
CFRP Tail Of
Helicopter
Common Composites
Cont..
Boron Fiber Reinforced Graphite
Boron fiber composites, according to
"Composite Materials for Aircraft
Structures," were first discovered in 1959
and were later developed into a high-
performance material. During the 1970s,
they were used in constructing the F-14
and F-15 military planes.
Given its large diameter--between 100 and
140 micrometers--boron fiber has a high
bending stiffness that limits its usage in
smaller more complex aircraft parts. This
characteristic distinguishes it from carbon
fiber, whose smaller diameter brings
greater flexibility.
Common Composites
Cont
Aluminum-Si-C(Ti)
Aluminum-(Silicon Carbide) is a metal-
ceramic composite material consisting of
silicon carbide particles dispersed in a
matrix of aluminum alloy. It combines the
benefits of high thermal conductivity
of metal and low CTE (coefficient of
thermal expansion) of ceramic.
With its composite features, Al-SiC is an
advanced packaging material for high
technology thermal management. Al-SiC is
compatible with a wide range of metallic
and ceramic substrate and plating
materials used in microelectronic
packaging for aerospace, automotive, Al-Si-C Substrate
microwave applications. Al-SiC allows for
a new packaging technology.
Manufacturing Processes
for Aerospace Composites
Autoclaving involves applying hydrostatic pressure at curing temperature which
helps in removal of voids and improvement of component reliability
Manufacturing Processes
Cont....
Manufacturing Processes Cont.......
Benefits of Composites in Aviation
Industry
Composites reduce the weight of aircraft because of high
specific strength
Natural composites like bone and wood have self healing characteristics
Composites are also being developed which have self healing properties:
an advancing crack is blunted by self healing mechanism and stress
intensity is reduced