AMT 216- COMPOSITE

Introduction

 Composite materials are quickly becoming recognized as the most substance for fabrication of
aircraft parts.

 The term composites are used to describe two or more materials that are combined to form a
much stronger structure than either material by it. The resulting material has characteristics that
are not a characteristic of the components in isolation.

 The concept of composite material is not new. The eldest manmade building material, adobe, is
a composite formula. Adobe is produced by combining two dissimilar components (mud and
straw) to form building bricks.

COMPOSITE STRUCTURE

 Basic Composite

 Advance Composite

 BASIC COMPOSITE

 It was believed that the first use of a basic composite was by the Egyptians and Chinese
over 3000 years ago to make bricks of mud and straw.

 ADVANCE COMPOSITE

 Replace heavy/dense metal structural components with ones of stronger, lighter-weight

 Allow light-weight aircraft to carry larger payloads, farther distances using less fuel.

 In space application more payload in orbit at less cost per pound

 ADVANTAGES

 HIGH STRENGTH = WEIGHT RATIO

 20% weight deductions were achieved when aluminum parts are replaced with
composite structure

WEIGHT DEDUCTIONS =MORE CARGO

=SAVE FUEL

=MORE PASSENGER CAN BE CARRIED

 ADVANTAGES

• High strength and stiffness

• Light weight

• Corrosion resistance (long life)

• Design and formulation flexibility

• Fatigue resistance

• Good damping characteristics

• Low thermal expansion

DISADVANTAGES

• Reduces Lifespan of makers

• Difficult to repair

• Difficult processing into parts

• High cost

Composites are combinations of two or more materials that differ in composition or form. The constituents
or elements that make up the composite retain their individual identities. In other words, the individual
elements do not dissolve or otherwise merge into each other. Each can be physically identified, and
exhibits a boundary between each other

COMPOSITE ELEMENTS
 Matrix

- is generally in liquid form

- serves as a bonding substance

 Reinforcing Materials

- is a solid material

- give the primary strength

 Core Material

- third component
Following are the five most common types of reinforcing fibers used in aircraft composites.

1.FIBERGLASS (GLASS CLOTH)

Fiberglass is made from small strands of molten silica glass that are spun together and woven into cloth.
Many different weaves of fiberglass are available, depending on a particular application.
Fiberglass is usually a white gleaming cloth. The widespread availability of fiberglass and its low cost make it one of the
most common reinforcing fibers utilized in aircraft non-structural composites.

One of the disadvantages of fiberglass is that it weighs more and has less strength than most other
composite fibers.

The two most common types of fiberglass are S-glass and E-glass. E-glass

1.S-glass is produced from magnesia-alumina-silicate, and is used where a very high tensile
strength fiberglass is needed.

2.E-glass, otherwise known as "electric glass" because of its high resistivity to current flow, is
produced from borosilicate glass and is the most common type of fiberglass used for reinforce-
ment.

2. ARAMID

In the early 1970s, DuPont3 introduced aramid, an organic aromatic-polymide polymer, commercially
known as Kevlar3. Aramid exhibits high tensile strength, exceptional flexibility, high tensile stiffness, low
compressive properties, and excellent toughness.

Aramid fiber is usually characterized by its yellow color, and as with most reinforcing fibers, comes in various grades and
weaves for different uses. Kevlar 493 is predominantly used in aircraft composite reinforced plastics; both in thermoplastic
and thermosetting resin systems.

Aramid fibers are non-conductive and produce no galvanic reaction with metals. Another important
advantage is its strength-to-weight ratio; it is very light compared to other composite materials. Aramid-
reinforced composites also demonstrate excellent vibration-damping characteristics in addition to a high
degree of shatter and fatigue resistance.

A disadvantage to aramid is that it stretches, which can cause problems when it is cut. Drilling aramid can
also be a problem if the drill bit grabs a fiber and pulls until it stretches to its breaking point.

1. CARBON/GRAPHITE

Carbon fibers are produced in an inert atmosphere by the pyrolysis of organic fibers such as rayon, poly-
acrylonitrile, and pitch. The term carbon is often interchangeable with the term graphite.

However, carbon fibers and graphite fibers differ in the temperature at which they are produced. Carbon
fibers are typically carbonized at approximately 24003 F and composed of 93% to 95% carbon, while
graphite fibers are produced at approximately 34503 to 54503 F and are more than 99% carbon.
. In general, Americans refer to carbon fibers as "graphite" fiber, while Europeans refer to it as carbon fiber. Carbon
actually describes the fiber more correctly, because it contains no graphite structure. Carbon/graphite is a black fiber that is
very strong, stiff, and used primarily for its rigid strength characteristics. Fiber composites are used to fabricate primary
structural components such as the ribs and skin surfaces of the wings.

Advantages to carbon/graphite materials are in their high compressive strength and degree of stiff-
ness.

Carbon/graphite materials are kept separate from aluminum components when sealants and corrosion
barriers, such as fiberglass, are placed at the interfaces between composites and metals. To further resist
galvanic corrosion, anodize, prime, and paint any aluminum surfaces prior to assembly with
carbon/graphite material.

2. BORON

Boron fibers are made by depositing the element boron onto a thin filament of tungsten. The resulting
fiber is approximately .004 inch in diameter, has excellent compressive strength and stiffness, and is
extremely hard.

Boron is not commonly used in civil aviation because it can be hazardous to work with, and is extremely
expensive

3. CERAMIC

Ceramic fibers are used where a high-temperature application is needed. This form of composite will
retain most of its strength and flexibility at temperatures up to 2,2004 F. Tiles on the Space Shuttle are
made of a special ceramic composite that dissipates heat quickly.

FIBER SCIENCE

The strength of a reinforcing material within a composite is dependent upon the weave of the material, the
wetting process (how the matrix is applied), filament tensile strength, and the design of the part.

The strength and stiffness of a composite buildup depends upon the orientation of the plies relative to
the load direction while a sheet metal component will have the same strength no matter in which
direction it is tested.

FABRIC ORIENTATION

When working with composite fibers, it is important to understand the construction and orientation of
the fabric because all design, manufacturing, and repair work begins with the orientation of the fabric.
  Warp

The warp of threads in a section of fabric run the length of the fabric as it comes off the roll or bolt. Warp
direction is designated as 05.

 Weft/Fill

Weft or fill threads of the fabric are those that run perpendicular (905) to the warp fibers. The weft
threads interweave with the warp threads to create the reinforcing cloth.

 Selvage Edge

The selvage edge of the fabric is the tightly woven edge parallel to the warp direction, which prevents
edges from unraveling.

 Bias

The bias is the fiber orientation that runs at a 455 angle (diagonal) to the warp threads. The bias
allows for manipulation of the fabric to form contoured shapes

FABRIC STYLES

Fabrics used in composite construction are manufactured in several different styles: unidirectional, bi-
directional, multidirectional, and mat. Component designers can use any or all of these fabric styles,
depending on the strength and flexibility requirements of the component part.

 Unidirectional

Unidirectional fiber orientation is one in which all of the major fibers run in one direction, giving the
majority of its strength in a single direction. This type of fabric is not woven together, meaning that there
are no fill fibers.
Unidirectional fabrics are not woven together. Warp fibers run parallel to each other and are kept in place by small cross
threads. The strength of this type of fabric lies in the warp direction, making it imperative to properly lay out the fabric.
  Bi-directional/Multi-directional

Bi-directional or multi-directional fabric orientation calls for the fibers to run in two or more directions. Bi-
directional fabrics are woven with the warp threads usually outnumbering the weft, so there is usually
more strength in the warp direction than the fill

Another type of bi-directional material is the intraply hybrid fabric. This type of fabric is woven from
different types of fibers. Intraply hybrid fabrics give composites specific strength, flexibility, and durability
characteristics, depending on the combination and proportion of the fibers woven together.

 Mats

Mat fabrics consist of chopped fibers compressed together and typically used in combination with woven
or unidirectional fabrics. A mat is not as strong as a unidirectional or bi-directional fabric, and is
therefore is not commonly used alone in repair work

WOVEN FABRIC WEAVES

Fabrics are woven together in a number of weaves and weights. Fabrics are more resistant to fiber
breakdown, delamination, and more damage tolerant than undirectional material.

The most common weaves used in advanced composite aircraft construction are plain and satin.

 The plain weaves is a simple pattern in which wrap and fill yarns alternative over and
under each other. Plain waves fabrics are popular for wet lay-up because they are easy
to impregnate with resin.
 Satin weaves are very common for repair applications. They are made by floating warp
yarns over several fill yarns and under one fill yarn in a repetitious pattern. It is called
satin wave because it produces a satiny finish by exposing more warp threads on the
front

MATRIX SYSTEMS
The function of the matrix in a composite is to hold the reinforcing fibers in a desired position. It also gives
the composite strength and transfers external stresses to the fibers. The ability of the matrix to transfer
stress is the key to the strength of a composite structure.

Resin is an organic polymer used as a matrix to contain the reinforcing fibers in a composite material.

Resin matrix systems are a type of plastic and include two general categories: thermoplastic and
thermosetting.

 THERMOPLASTIC RESINS

Thermoplastic resins use heat to form the part into the desired shape. However, this shape is not neces-
sarily permanent. If a thermoplastic resin is reheated, it will soften and could easily change shape.

 THERMOSETTING RESINS

Thermosetting resins use heat to form and irreversibly set the shape of the part. Thermosetting plastics,
once cured, cannot be reformed even if they are reheated. At this time, most structural airframe
applications are constructed with thermosetting resins.
 Polyester Resin

Polyester resin, an early thermosetting matrix formula, is mainly used with fiberglass composites to create
nonstructural applications such as fairings, spinners, and aircraft trim.

While fiberglass possesses many virtues, its greatest limitation lies in its lack of structural rigidity. Polyester
resins give fiberglass cohesiveness and rigidity. However, polyester resin/fiberglass composites do not offer
sufficient strength to fabricate primary structural members.

 poxy Resins

Most of the newer aircraft composite matrix-formulas utilize epoxy resins, which are thermoset plastic
resins. Epoxy resin matrices are two-part systems consisting of a resin and a catalyst. The catalyst acts as a
curing agent by initiating the chemical reaction of the hardening epoxy.

Epoxy resin systems are well known for their outstanding adhesion, strength, and resistance to
moisture and chemicals. They are also useful for bonding nonporous and dissimilar materials, such as
metal parts to composite components. The manner in which the joints are designed, and how the
surfaces are prepared, determines the quality of the bond.

 ADHESIVES

Resins come in different forms. Resins used for laminating are generally thinner, to allow proper saturation
of the reinforcing fibers. Others are used for bonding and are typically known as adhesives because
they glue parts together. Adhesive resins and catalysts are available either in pre-mixed quantities or in
separate containers.

Safety
When working with composite materials, correct safety precautions must be observed. Pay attention to
the material safety date sheet (MSDS). On the MSDS you will find the following information:

 Health precautions

 Flammability of the materials

 Ventilation requirements

 Information for health professionals in case of an accidents

Safety Precautions

Some of the materials are very dangerous and can cause allergic reactions, so take care if you are
working with these materials and observe safety precaution:

 Do not let any of the materials come into contact with your skin or with your clothes

 Do not inhale vapors

 Do not be untidy

 Do not wash your skin with powerful solvents

 So not eat, drink or smoke in work areas

 Do not machine materials without wearing protective clothing and a dust mask