Composites

Aircraft Non-metallic Structures

737 – Rudder, elevators, radome, wing to body fairings, floorboards, galley walls,
lavatory

Airbus, 757, 767 – has the almost the same components that are composite

SRM – Structural Repair Manual – for structures and composites

OHM – Overhaul Manual – maintenance repair and composites

Kruger flaps – leading edge

Composites materials

Honeycomb –

Carbon/Graphite – good for primary structural applications; good compressive

strength, is highly rigid when in a matrix and has high fatigue resistance; requires
lightening protection; corrosive to aluminum

Aramid – Aramid fibers are a class of heat-resistant and strong synthetic

fibers. They are used in aerospace and military applications, for ballistic
rated body armor fabric, and as an asbestos substitute. The name is a
shortened form of "aromatic polyamide". They are fibers in which the chain
molecules are highly oriented along the fiber axis, so the strength of the
chemical bond can be exploited.
Fiberglass –

Boron – strictly used in military- F14, like Kevlar- expensive; usually come in
unidirectional; has excellent compressive strength and stiffness, and is extremely
hard.

Ceramic – hi heat resistance, they can be used in areas up to 2,200degrees F;

popular for firewall

Composites also used

1. Primary Structural
2. Secondary Structural

Strength to weight ratio is high

Advantages

1. High strength to weight ratio 20% saving

2. Cost effective design – design to be flexible, resistant to vibration, stress
fatigue
3. Composites do not corrode
 4. Reduce wear

Fiberglass – glass fibers that have been spun into yarn and woven into fabric; used
for non-structural repairs

Three types of fiberglass cloth

1. E-glass – hi electrical resistance; low cost

2. S-glass - hi tensile strength, 40% stronger than E and can stand higher
temps; wings; flight controls
3. C-glass – higher chemical resistance; battery compartment, bilge area,
anywhere there is hydraulic fluids

Composites are highly susceptible to impact damage, with the extent of damage
being visually difficult to determine

Unidirectional – strength in only one direction

Anisotropic – different strengths when measured in different directions

Quasi-isotropic – same strength in different directions

Tensile strength but weak compressive loads

Compressive strength

Strengths are determined by fiber orientation patterns.

Maximum strength is parallel to the fibers, and loads at right angles to the fibers
tend to break only the matrix.

Fibers carry the physical loads and provide most of the strength of composites.

Kevlar – excellent tensile strength and toughness, but inferior compressive strength
when compared to graphite; density and cost are lower than graphite; need special
scissors to cut because of stretching; need brad-point drill made for Arimid fabric;
fuzzy holes can result from improper cutting and drilling, these fuzzy holes can
absorb moisture, the moisture will cause matrix to de-laminate

Matrix (Resin)

– Homogenous resin that, when cured, forms the binder that holds the fibers
together and transfers the loads to the fibers
– Epoxy the most dominant in aviation
– Epoxy provide high mechanical and fatigue strength, excellent dimensional
stability, corrosion resistance and inter-laminar bond, good electrical
properties and very low water absorption
– The changing of the matrix properties by chemical reaction is called the cure

Resins
 – Its purpose is not only to give the flexible glass cloth form, but also to carry
loads from one fiber to the next.

Polyester Resin

– Isn’t used on structural components; you find at your local hardware store; it
is used in aviation for fabricating forms and other tooling
– The hardening process generates its own heat from a chemical reaction of
the resin and hardener
– Not enough catalyst will slow down the hardening process to the point of
unsuitability
– Too much harder and the mixture will generate so much heat that you will
have thermal runaway

Epoxy Resin

– It hardens by a chemical process known as cross-linking

– May not cure if too much resin is used
– Pot life –the specific time period in which it must be used

Reinforce Plastic

Warp – threads that run from one end of a roll of fabric to the other

Woof – Also known as fill or weft, the threads that run side-to-side and actually
make the collection of long threads into cloth

Selvage – when the woof runs to the side of the cloth and turns around the goes
back to the other side, it produces a selvage edge. It doesn’t lay down well and is
generally trimmed.

Bias - Warp and woof threads run parallel to the length, or 90degree, and are
difficult to form around a curve. By cutting the material at a 45degree angle to the
warp, it can be made to smoothly fit a curve

Hot Bonding

– The process that allows the technician to actually control the bonding and
curing process
– The items that are critical to the integrity of the cured repair are:
1. Resin quantity
2. Fiber Contact
3. Vacuum pressure
4. Excess resin removal
5. Applied heat
– If there is too much resin, the resin will crack under load b4 proper amount is
transferred to the next fiber