Composite Defined - The term composite is used to described two or more materials that are combined to form a structure

that is much stronger than the individual components.

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Combination of Composite * Composite Materials * Matrix * Core Materials

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Advantages of Composite * High strength to weight ratio * Strong as a metal part * Reduced drag

* Number of parts and fasteners may be reduced

* Composites dont corrode like metal does.

* Reduced wear
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Uses of Composites * Helicopters * Military Aircraft * Commercial Aircraft

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Kinds of Reinforcing Fibers 1. Fiber Glass (Glass cloth) 2. Aramid 3. Carbon / Graphite 4. Boron

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Fiber Glass (Glass cloth) - is made from small strands of multi silicon glass that are span together and woven into cloth. - widespread availability and its low cost make fiber glass one of the most popular re-enforcing fibers.
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a. E - Glass
- also known as Electric Glass for its high electrical resistance. - it is a borosilicate glass commonly used for re-enforcement because of its low cost and good strength characteristics.

b. S - Glass
- it is a magnesia alumina silicate glass that is up to 40 percent stronger that E-Glass and Retain its strength characteristics at higher temperature. - S Glass is used were a very high tensile strength fiber glass is needed.
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c. C- Glass

- is used in materials that require chemical resistance.

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Aramid / Kevlar
- is usually characterized by its yellow color, light weight tensile strength and remarkable flexibility.

- Bullet proof according to the grade.

Example: Kevlar 129 is bullet proof material Kevlar 29 is used for boats.
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Carbon / Graphite
- is a very strong, stiff reenforcement. - this black is very strong, stiff and used for its rigid strength characteristics. - electrically conductive.

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Boron
- is made by depositing the element boron into a thin filament of tungsten. - has excellent compressive strength and stiffness and is extremely hard.

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Ceramic
- are used when a high temperature application is needed. - retains a temperature of 2, 200F. Examples: Ceramic is used for the tile of the space shuttle. - dissipates the heat quickly.

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Fiber Science
- the selective placement of fibers needed to obtain the greatest amount of strength in various application.

Victors of fiber placement

1. 0 plies (to react the axial loads) warp 2. 45 plies (react to shear victors) bias 3. 90 plies (to react to side loads) wft
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Matrix Materials
1. Resin 2. Catalyst / Hardener

Two (2) types of Plastic Risens

1. Thermoplastics use heat to form the past into the desired shape. Example: Aircraft Windshield 2. Thermo set resins use heat to force and set the shape of the part permanently Example: Structural airframe application
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Epoxy Resin System

- are type of thermo setting plastic resin well known for their outstanding adhesion, strength and their resistance to moisture and chemicals.
- most common matrix system used in composite fabrication and repair, because:

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1. Extremely flexible in terms of their applications. 2. Exhibits good adhesive characteristics when used with a broad range of cloth re-enforcing materials, fillers and substrates. 3. After being cared, epoxy resins are resistance to deterioration by water, acids, bases many chemicals solvents and Vice Versa.
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4. Epoxy resins are easily cased at room temperature or at slightly elevated temperatures and they do not require exotic equipment to process. 5. Epoxy resins are very dimensionally stable they shrink very little during the curing process and very acceptable for use of structural parts, mold fabrication material, or tooling fabrication material.
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6. The resins exhibit the strategist adhesive characteristics of any known polymeric material. 7. Superior strength long shelf if more economical for fabrication and repair.

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Working with resin and Catalyst

- when working with resins and catalyst or caring agents, always follow the procedures specified in the structural repair manual. - if the resin system requires refrigerated storage allow each part to warm up to room temperature before weighing and mixing. - mix resins in proper ratios. - mix resins for the proper amount of time
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- do not mixed large amounts together. - all resins care by chemical reaction, but some generate their own heat, thus accelerating the curing. - be sure to know the resins pot life before starting . - spread the matrix all over the lay-up in proper amount to avoid resin rich on resin lean.

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Fillers
- are thixotropic agent are materials that are added to resins to control viscosity and weight, to increase profile and strength and to make the applications of the resin easier.

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Types of Fillers
1. Micro Balloons are small spheres of plastic or glasses. 2. Chopped fibers or flox type of fiber cut into a desired length.

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Pre-impregnated Materials
- are fabrics that have the resin system already impregnated into the fabric.

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Advantages of the Pre-Pregs

1. The pre-preg contains the proper amount of matrix. 2. The re-enforcing fibers are completely
encapsulated with the matrix. 3. Pre-preg fabric eliminates the use to manually weigh and mix components. 4. Pre-preg materials produce a stronger component or repair.
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Disadvantages of the Pre-Pregs

1. Many pre-pregs must be stored in a freezer. 2. Many companies do not want to sell small quantities of a specific weave and resin system, so a full roll must be purchased. 3. Pre-pregs material is much more expensive than raw fabric that can be impregnated with the resin system. 4. Composite components and materials have not yet been standardized.
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Core Materials
- it is the central member of an assembly.
Types of Core Materials
- Honeycomb - Foams - Balsa wood

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Why use core material?

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Why use core material?

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Applying Pressures

- this must be applied to the surface during the curing operation until the component is fully cured. The purpose of applying mechanical pressures is to:

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1. Remove excess resin from the components ensuring the proper ration of resin to fiber re-enforcement. 2. Remove air trapped between layers. 3. Maintain the contour of the repair relative to the original part. 4. Hold the repair securely, preventing any shifting of the patches during the curing process. 5. Compact the fiber layers together.
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Methods of Applying Pressures a. Shot bags b. Clecos c. Spring Clamps d. Vacuum Bagging

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Shot Bags

- this must be applied to the surface during the curing operation until the component is fully cured.

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Clecos

- used in conjunction with pre-shaped cauls plates to apply pressure to the repair.

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Spring Clamps

- allow the pressure to continue even after the res in flow.

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Vacuum Bagging

- the most effective method of applying pressure to a repair and is recommended for the use whenever possible.

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Vacuum Bagging Process

- once the repair is made and the patches in place, the area is covered with a parting film or a parting fabric (Peel Ply) - a bleeder material is an absorbent material that is either placed around the edges.
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- a breather material is placed on one side of the repair to allow air to flow through it and up through the vacuum valve. - the two vacuum valve is placed on top of the breather material to remove the air from inside the vacuum bag.
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- a sealant type is attached around the edges of the repair. - vacuum bagging film is laid out the repair area and the edge are worked out into the sealant tape to produce a airtight seal.
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- the bagging film should be slightly pressed into the tape until it forms an airtight seal that covers the part. - a slit is cut into the bagging film over the vacuum base, then the vacuum valve is inserted into the base and sealed airtight. - the vacuum source is connected to the vacuum hose and turned on.
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Vacuum Leak Check

- it is done to make sure the bag is sealed properly. Vacuum bagging Films
- are used to cover the components an seal out air.
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Sealant Tape - are used to maintain a positive seal between the surface of the original part and the bagging films. Peel Ply
- a nylon or polyester release fabric may be used next to the wet resin during operation to transfer excess resin to the bleeder material without sticking to the part.
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Bleeders - are cotton like absorbent material used to soak up excess resins.

Breathers
- are cottony materials that allow air to flow through a valve or over the surface of the part throughout the vacuum bagged area.
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Methods of Curing
a. Room temperature curing b. heat curing c. Step curing d. ramp and Soak curing e. Hear blanket f. heat guns g. Heat lamps h. Oven Curing i. Auto Claves
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Room Temperature Curing - some repairs may be cured at room temperature from 65 - 80 F over a time span of 8-24 hours, depending on the type of resin system used.

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Heat Curing - the most widely accepted method of curing structural composites, employs resins that cure only at higher temperature.

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Step Curing - is used with a manually operated controller and requires the technician to make the adjustments manually at specific time intervals.

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Ramp and Soak Curing - a programmable controller produces a more sophisticated and accurate curing than the step curing process.

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Heat Blankets - are probably the most widely accepted form of applying heat to a composite component for the work.

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Heat Lamps - have been used to cure composite parts for many years

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Oven Curing offer controlled, uniform temperature over all surfaces.

Auto Claves - usually used in the manufactures of composites and are not used in the repair procedures unless the part must be remanufactured.
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Assessment and Repair Classification of damage: *Cosmetic Defects a defects on the outer surface that does not involve damage to the structural reinforcing fibers. * Impact damage occurs when a foreign objects strikes the part.
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*Delamination is the separation of fabric layers of materials in a laminate *Cracks occur in advanced composite structures just as in metallic ones. * Hole damage occur from impact, over-torquing fasteners, or a result of fasteners pull-through.
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Inspection methodology 1. Visual Inspection - used to detects cracks surface irregularities and surface detects such as delamination and blistering. 2. Coin tap test one of the most important tools used to detect internal flaws or delamination.
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Algie composite airframe

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Lancair ES composite parts

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Velocity composite parts

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