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The magic fibre composites are working hard all around you The latest aeroplanes use more

than 35+++% of these magic fibres in various combinations for reducing weight ,increasing fuel efficency, Composites Used In Aerospace

Weight is everything when it comes to heavier-than-air machines, and designers have striven continuously to improve lift to weight ratios since man first took to the air. Composite materials have played a major part in weight reduction, and today there are three main types in use: carbon fiber-, glass- and aramidreinforced epoxy.; there are others, such as boron-reinforced (itself a composite formed on a tungsten core).

Since 1987, the use of composites in aerospace has doubled every five years, and new composites regularly appear. Where Composites are Used Composites are versatile, used for both structural applications and components, in all aircraft and spacecraft, from hot air balloon gondolas and gliders, to passenger airliners, fighter planes and the Space Shuttle. Applications range from complete airplanes such as the Beech Starship, to wing assemblies, helicopter rotor blades, propellers, seats and instrument enclosures.

The types have different mechanical properties and are used in different areas of aircraft construction. Carbon fiber for example, has unique fatigue behavior and is brittle, as Rolls Royce discovered in the 1960's when the innovative RB211 jet engine with carbon fiber compressor blades failed catastrophically due to birdstrikes.

Whereas an aluminium wing has a known metal fatigue lifetime, carbon fiber is much less predictable (but dramatically improving everyday), but boron works well (such as in the wing of the Advanced Tactical Fighter). Aramid fibers ('Kevlar' is a well-known proprietary brand owned by DuPont) are widely used in honeycomb sheet form to construct very stiff, very light bulkhead, fuel tanks and floors. They are also used in leading- and trailing-edge wing components.

In an experimental program, Boeing successfully used 1,500 composite parts to replace 11,000 metal components in a helicopter. The use of composite-based components in place of metal as part of maintenance cycles is growing rapidly in commercial and leisure aviation.

Overall, carbon fiber is the most widely used composite fiber in aerospace applications.

Advantages of Composites in Aerospace

We have already touched on a few, such as weight saving, but here is a full list:

Weight reduction - savings in the range 20%-50% are often quoted. It is easy to assemble complex components using automated layup machinery and rotational molding processes. Monocoque ('single-shell') molded structures deliver higher strength at much lower weight. Mechanical properties can be tailored by 'lay-up' design, with tapering thicknesses of reinforcing cloth and cloth orientation. Thermal stability of composites means they don't expand/contract excessively with change in temperature (for example a 90F runway to -67F at 35,000 feet in a matter of minutes). High impact resistance - Kevlar (aramid) armor shields planes, too - for example, reducing accidental damage to the engine pylons which carry engine controls and fuel lines. High damage tolerance improves accident survivability. 'Galvanic' - electrical - corrosion problems which would occur when two dissimilar metals are in contact (particularly in humid marine environments) are avoided. (Here non-conductive fiberglass plays a roll.)

Combination fatigue/corrosion problems are virtually eliminated.

The Future of Composites in Aerospace

With ever increasing fuel costs and environmental lobbying, commercial flying is under sustained pressure to improve performance, and weight reduction is a key factor in the equation.

Beyond the day-to-day operating costs, the aircraft maintenance programs can be simplified by component count reduction and corrosion reduction. The competitive nature of the aircraft construction business ensures that any opportunity to reduce operating costs is explored and exploited wherever possible.

Competition exists in the military too, with continuous pressure to increase payload and range, flight performance characteristics and 'survivability', not only of airplanes, but of missiles, too.

Composite technology continues to advance, and the advent of new types such as basalt and carbon nanotube forms is certain to accelerate and extend composite usage. When it comes to aerospace, composite materials are here to stay. About Carbon Fiber Carbon fiber (also known as carbon fibre) is the super hero of the materials world its one of the strongest and most lightweight materials available on the market today. Five times stronger than steel and one third its weight, carbon fiber composites are often used in aerospace and aviation, civil engineering, military, car racing and other competitive sports applications. Carbon Fiber Fabric Carbon fiber starts as very, very thin strands of fiber that are finer than a human hair. These strands are twisted together like yarn (called a tow) and woven into carbon fiber fabric which typically comes in 3k, 6k and 12k weights. A 3k fabric has 3,000 strands of carbon in each tow while a heavier weight 6k fabric has 6,000 strands per tow.

Carbon fiber fabric comes in a variety of weaves that have different strength properties. The most common are plain weave, harness satin weave, twill weave and unidirectional.

Weave is critical for two reasons appearance and functionality. Each weave looks very different and sometimes people prefer the look of a certain weave for a specific application. Also, weave impacts product strength. A unidirectional weave creates a carbon fiber sheet thats very strong in the direction of the fibers,

but weak in the opposite direction. Plain and twill weaves, on the other hand, have more uniform strength since theyre strongest at the points where the fibers cross in either direction. At Protech, we use a 6k 2x2 twill weave for our standard product line; weve chosen it for its all around strength and good looks. We also work with a variety of other fabrics for custom orders. Carbon Fiber Composites To make a carbon fiber sheet (also known as a composite), carbon fiber fabric is saturated or infused with epoxy resins and heated at high temperatures. Shaped pieces are made by layering several pieces of fabric over a mold, saturating them with resin and heating it until the resin has infused through all layers. Advantages of Carbon Fiber

Carbon fiber composites stands out from the crowd for several reasons. Here are a few:

Lightweight carbon fiber is a low density material with a very high strength to weight ratio

High tensile strength one of the strongest of all commercial reinforcing fibers when it comes to tension, carbon fiber is very difficult to stretch or bend

Low thermal expansion carbon fiber will expand or contract much less in hot or cold conditions than materials like steel and aluminum

Exceptional durability carbon fiber has superior fatigue properties compared to metal, meaning components made of carbon fiber wont wear out as quickly under the stress of constant use

Corrosion-resistance when made with the appropriate resins, carbon fiber is one of the most corrosionresistant materials available

Radiolucence carbon fiber is transparent to radiation and invisible in x-rays, making it valuable for usage in medical equipment and facilities

Electrical conductivity carbon fiber composites are an excellent conductor of electricity

Ultra-violet resistant carbon fiber can be UV resistant with use of the proper resins

Disadvantages Carbon fiber will break or shatter when its compressed, pushed beyond its strength capabilities or exposed to high impact. It will crack if hit by a hammer. Machining and holes can also create weak areas that may increase its likelihood of breaking. Relative cost carbon fiber is a high quality material with a price to match. While prices have dropped significantly in the past five years, demand has not increased enough to increase the supply substantially. As a result, prices will likely remain the same for the near future.

Aramid Hybrid Fiber Fabrics Aramid Fiber Kevlar Twaron Hybrids Aramid fibers properties make it suitable for many industries. It can be found in optical fiber, cables, ballistics (helmets, vests & armor), elastomer reinforcements (hoses, transmission belts & conveyer belts), tires, linear tension members (rope & Cable), Heat & Cut protection (boots, clothing, aprons, gloves & helmets) and our favorite Composites.

Due to its low density, stiffness and high resistance to damage it is widely used in the marine and transportation industries to build lighter, stronger, stiffer and more durable parts. Aramid is ideal for hulls, in fact almost all of the boats in the Volvo Ocean Race use Aramid reinforcements. Many high performance power boats and high speed ferries also take advantage of weight savings and increased fatigue resistance of this high performance fiber.

With todays increasing fuel costs and demand for increased speeds you can not debate that even recreational power and sail boats can benefit from the weight savings and increased strength using Aramid and Aramid/Fiberglass hybrids. You are also building in value by using a damage and fatigue resistant fiber that is sure to extend the usable life of you composite parts.

Features Benefits Excellent Tensile Strength: 3620 MPa (525 ksi) Hard to cut, hard to penetrate on impact. Excellent for parts that will take sharp impact loads such as canoes, off shore sail and power boats. Low Density: 1.44 gm/cm3 (.052 lb/in3) The lowest weight of all major reinforcing fibers make this an excellent bulk builder in single skinned infused laminates where skin bulking and low laminate weight are a concern.

Good Stiffness: 131 GPa (19 msi) For its low weight, aramid offers laminate bulk to improve thickness without a weight penalty as well as double the stiffness of E-glass. Excellent Toughness Aramid fiber will yield prior to breaking and is very difficult to fail even with sharp impact loads. Works well as a hybrid material Aramids are successfully combined with E and S-Glass as well as carbon fibers to enhance the laminate impact and thickness properties at the lowest possible weight. Negative Coefficient of linear expansion: -4.3 x 106 (-2.4 x 106) For high temperature applications this low CTE can provide very stable mountings for electrical components. Low Dielectric Constant: 4 at 1 MHz

Good radar transparency Cautions with Aramid Fiber Aramid fibers are difficult to cut and grind so installation is somewhat difficult. It is important to have the proper cutting and grinding tools to make this work easier. Builders typically use a glass cloth on the outside skin to make repair of paints etc. easier. Aramid fibers are lower in compression than Glass or Carbon. For this reason many builders choose hybrid materials to enhance the compression properties. Aramid fibers can pick up moisture very easily and must be properly impregnated and protected from water infusion. Aramid fibers are degradated by UV light and must be properly coated (painted). Aramid fibers are more difficult to properly impregnate and care must be taken to be sure that they are fully wet out. They tend to have lower adhesion than other fibers so good quality resins are recommended such as Vinyl Ester or Epoxy resins. Carbon is extremely strong in tension and compression and (most importantly) is by far the stiffest of the fibers. However, it is brittle, so the fiber's aren't as tough as kevlar or glass. This is very important, because composites have such a strong ultimate strength that they are usually designed more for stiffness than strength. Bottom line: Carbon will give the stiffest, most flutter resistant wings, but isn't as tough as kevlar or S-glass Think of kevlar like leather, carbon fiber like wood, and fiberglass like, uh, glass fiber.

Imagine sanding leather that's what it's like to sand kevlar. But it has great toughness and *relative* flexibility.

Carbon fiber is more rigid and sands well slopeiron has a perfect description of it's applications above.

Fiberglass is still my favorite. Not as flexible as kevlar but more so than carbon. S-glass is almost as strong as carbon in the same application (just as Target!). Epoxy likes glass more than it does kevlar and glass is much, much easier to cut. Fiberglass sands well.

They all have their place, obviously, but use glass until you get comfortable with the processes (curing times, wetting out, etc.). That will save you some $$ and probably some heartache. Carbon fiber is black. Kevlar is yellow. Fiberglass is white. Dasicaly different areas of application each of them are more suited High strength CARBON Carbon has great compression/tension strength, kevlar has great surface strength (I am not sure what the correct term is but it is strong in a sheet against deflective forces which is why it makes good bullet proof vests and wing skins) and fiberglass is just a nice all around cheaper option.

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