UNIT - IT.

Q1.What are the different types of plastics used in aircraft? Explain each briefly.
PLASTICS:

Commonly used term 10 denote any of the therll1opl:lstlc or Ihermosetting, flolymers used in modern ilircrafl
construction.

According to their chemicill sources, plaslics may he classified in to foul general grours
1. Natural resins.
2. Synthetic resins.
3. Protein plastics.
4 Cellulose plilSlics

THERMOPLASTICS

Thermoplastics soften on heating and can be shaped more (han once under heat and pressure.

Thermoplastics can be shaped using a wide range of processing techniques like, injection, compression,
blow moulding, extrusion, casting.
Two chemical structure on which thermoplastic properties based.
I Amorphous polymers of random molecular structure.
2.CrystaJline polymers of ordered molecular structure.
Amorphous polymers having the foJlowing properties:
Transparent, wide melting range, High crcep resistancc, rcstricted chemicill resistance.

Crystalline polymers having the following rroflerties:

Semi·transparent, good wear, fatigue and chemical resistance, sharp melting points.

THERMOSET PLASTICIS:

Are moulded to shape and are usually set by using suitable curing agent at ..:elevated lambient temp and
cannot be reshaped again ..

Thermosetting plastics are obtained in the form of viscous resins

Viscous .-. thick, high resistance (0 f!ow.
Resins m_ A family of natural or synthetic Ouids.

TRANSPARENT PLASTICS:

Transparent plastics having following properties:

1. Strong 2. Scratch resistant. 3. ColorIess. 4. Non-inflammable 5. Transparent.

6. Unaffected by sunlight or by temfl chnnges, molcl it to the desired shape.

PYRALIN;

Pyroxylin 11Ill'~cellulose plaslic Non-explosive. Less inflmnmable

pLEXIGAS TYPE is used for windshield.

Non-inflammable.
YINYLITE: Co-polymer resin of vinyl chloride nnd vinyl acetille.
Q3.Discuss about the maintenance and repair of plastic components.
MAINTENANCE OF PLASTICS:

Vision is so~it~I; so maintenance of transpar;;:;t-pI~slics is of the nlost i mportanL

Vision~is impaired as a result of chemical or physical acliolis or defects, so every efforts should be taken to
eliminate harmful action whil~ servicing aircraft.
CRAZING:
•

Hairline cracking in plastics caused by exposure to harmful solvents and iniproper maintenance.
Crazing appears as a network of cracks running in all directions over tlie surface of the plastics.
When cleaningexterior surface, always remove rings from the hands before washing. ,
.' .

When parked aircraft, may absorb enough

-.
heat to soften and distorted, unless certain precautions are taken .
..
:
-

'. ';" ."

~~Traniparent plastkshasptoperry of.~bsorbing the heat producing rays of tlie sun: so that the plastics can
hotter than the surrounding air inside or outside of the aircraft. .

Air inside the aircraft will transfer the heat radiated by the metal members in the aircraft to the plastic
enclosures by convection .
. To prevent deformation of plastics, of parked aircraft, when exposed to the sun the following precautions
are recommended.

I. I{air temp is below 100F, no special precautions are necessary. ,

2. If between'.!OOFand 120F;enclosures should be opened to permit free circulation oLair through
aircraft.~'7/""
3. If the temp is above 120F, enclosures must be opened and protected from the sun by a suitable cover "
which doesl-lOt cCHllein to contact with the transparent plastics. '
4. q..EANINGPLASTICS: Q5.Write the procedure to clean and maintenance of plastic.

, The best wayio~clean plastic surface is by flowing fresh water across the surface and thenusing'the hand
•
to gently r'errioveany particlesadhedngto
, ,_' '.' , .• !. ',"
'.> ", -
_'.' .•
the surface .. A mild soap and \Vater solution,:an_. " r",
.be usea, if
,

'., require~''vVheri'using cloth, preyent trapping particles in the cloth that can be damage the surfaces, as the.
c1oth'l's·'moVed()_verthe,suif~~e .. ,.' ',. " '. '"
Several comm6rclaLCleane.r:sJavMlable.·that can be used t6 clean plastics. The commercial materials are
·w A)qAN.P;NfI'I~!A~<:1:gQ~1P9~NT. that reduces the static buildup. ort the pllli)tic:.;The~ewaXes
·, will
, fillinsome·6tthe.fines~ratchesil1a:tappear
~ -~,·,··'·~····f~·._~.,
•...._ ~..:.~.,.:.,. ~-' - p' on plastic .•and improve the visual - clarity
-,",'".
to same ""'",:degre~e."
.'" ,
.'
'c ' -"Plast!<shb~Id.~o(be,~?b,ed·with :a dry cloth, since this is likely to scratch the surface arid canc'ause
a buildup.ofstaticel~c~ricity;+~.,::" ,;.. ," .' '.' .. ,' i", >"
Crazing ·istlleJorlmition of.a netwOrKofJine cracks in the surface of the materiaL., The effect .o(<;:.t:azingis.:"'.'
to destroy. , the clarity .....
-
of vision ihroughth6material
:.'"
'., ~ and to weaken the structure strength.:·:; .. '.'::'.:J.i;.;{;;,;<:;i:'
' - '" - - . '-'~•........ ~,. ,
"
· Manuals specify thetypes of c\eiming' agents suitable for the plastic windshieldsand windows}or,speci:fi<J*;~(~
aircrafC '·<:':2<:!\·.·<:;i£':.~.:·::'·\'?\'o:: i'< .. "'. "'HH' H"" ...•.... - ".' ':"., .>.' ,; ::h~,j;,;;~,ji'::j:'-t¥')~~;;
·Certai~eutra:i.p~troleu~;~olve~tssuchas kerosene, or naphtha-ciTeaningfluid are soinetlil1es:spe~lfie«(fC;~t0~
the removaIofoiJ or-grease.: If theseare,used, the surface should be dried as quickly as possible:a~d'the:Ii'it\~~~i
washedwithwaiei-anda~lddetergent.--· , .' ;":":~"'::;Z:}:
Paint may . need t6 b,e'removed from the clearplastic parts .. '" "':~~');''':
The technique used to remove the p~int depends upon the types of paint to be remove? >;: :.
Three techniques may be use~to reniovepaint. ·Oi.

I. Solvents'
2. Sand Blasting. 3. Trialene soap ..
Trialene soap may be used toremove acrylic based paints from Plexiglas.
Q12.Discuss in detail the cleaning procedure followed when cleaning exterior and interior surfaces of
the transparent plastic enclosures of aircraft.
REPAIR OF CRACKS

Cracks commonly aprear on the edges 01' a l1iec·e or !)Iaslic r<ldialing olll rroll1 a pressurcroint or mounting
Hole.
Ir the crack ]S ]11 Ihe pillll'S norm;lI vision are;l the panel should he replaced.
lr the crack is nOI ]n Ihe normal vision ;Irea. (he cracks should he stop drilled. *H****

--
The surface patch of the same malerial as the original material should be cui to extend beyond the edges of
the crack at least (1.91 cm) and formed to lay fully on [he surface contour.
The edges of the patch should be tapered as shown and the ratch spread with adhesive and positioned on
the surface of the panel being repaired. Pressure is then applied to the patch for. several hours. After 24
hours, the patch can be polished to achieve clean edges. **********

REPAIR OF HOLES:

When a hole is found in plastic wind shield or windows.

The hold is then dressed with a file and abrasive paper to remove rough edges. If a surface patch is to. be
installed, this completes the hole preraration. If a plug patch is to be installed, the hold should be trimined
out to a circle or oval that tapers toward.
For a plug patch, a rlug is cut from material thicker than original material. The plug is cut to be proper
size, and the taper is more severe than Ihat of the rrepared hole. The plug is heated and pressed in to the
hole to allow the plug to match the edges of the hole.
After the plug has cooled, adhesive is applied and the plug is installed in to the hole.
Then the plug trimmed by filling and sanding so that it is flush with the original panel on both sides.
The patched area is buffed and pal ished to a clear surface. *****

-\,.:
Q6.What is composite material? Write its advantages.
('UMPOSITL':l.

!v!ADE UP OF DIFFERENT PARTS

Cumposites are combill;:tion or material uillerillg 'In c()lnposllioll 01 jurlll. WIICIC ill'~' indl\'idua!
cunstitute'nts retain their separate identities and do Ilol ulssolvc or merge togcther

These separate constitutents act LOgethcr to give the ncces~;ary mcchanical sll'cnglh m stillness tu the
composite part.·
This definition refers to fibre as reinforcement in a resin matrix
Composite is made from two components i,e. a fibre and resin.

ADVANTAGES:

Low weight leads to ruel savings. I.e. 2()'fI, [0 4U':'!r. or weiglll is rl'lIUl'CU L"lJ/nparc 11' melal;
Excellent strength/weight.
Excellent Stillness/ weight ratio.
4. Easier to achieve smooth aerodynamic prorik Cor drag reduction.
5. Production cost is reduced.
6 Excellent resistance to corrosion, chemical attack and outdoor we;lthering.
Q7.Explain in detail about fibre glass composite in Morden aircraft construction
FIBRE GLASS:

Extremely thin Cibres oC glass may he woven in to a cloth 01' lightly packed in to a mat.

j=:POXY: A tlexible, ther1l10Selling resin made by the polymerisation or ;In epoxldc.

POLYESTER RESIN:

Synthetic resin, usually reinforced with fibre glass cloth or mat, and Llsed to Corm complex shapes for
aircraft structures.

High performance fibres such as boron, carbon, aramid, polyethylene.

Composites materials having a two phase struclure:

! A fibre which acts as the reinforcement.

2. A matrix which bonds and holds all the fibrcs.

Composite materials based on the mcch:lIlical properties oC a Cibre which has an outstanding tensile strength
and sti ffness.

These fibres are embedded' in to a matrix whole rule is to bond the fibres to keefl them align,~d ane! transfer
the loads applied to the element concerned.
The selection of matrices and fibres for aircraCt structurcs dcpel1d 011 the cnvironlllClllal conUillons With in
the flight enve!o[ie.

Industrial fibres are classiCied according to lheit' [it"Upnlies

I Glass ribre of mediulll strcngth.

:2 The high strength carbon fibrc
') The oorOI1 fibre.

ADVANCED COMPOSITES PROVIDINC; AN lOEAL SOLUTION TO THE DEMAND OF THE

AEROSPACE INDUSTRIES FOR LIGHTEr<, H1GH PERFORMANCE STRUCTURE
Q8.Write the notes on advanced composites
ADVANCED COMPOSITES

L· GI/\SS i'II\I~L
S- GLASS I-1I3RE
CARBON HIGH MODULUS
CARBON HIGH TENSILE FIBRE.
BORON HIGH TENSILE FIBRE.
ARAMTD (KELVAR - COMMERCIAl. NAMI:)

XA - standard high sll'ength filxes are used 1'01' aerospace produCIS.

XA - High strain fihres can be used I'm airrrame primary structures.

THE FIBRES MUST BE COMBINED WITH A MATRIX MATERIAL TO FORM A COMPOSITE.

~._--- FIBRE:
CARBON

High performance carbon fibres are usually made hy controlled [lyrolysis of POL Y- ACRY -NITRILE
TEXTILE PRECURSOR.
Pyrolysis means High Temperature burning.

.
ARAMID FIBRE:

Aramid fihre (kevlar) is designed for reinforcing plastic materials. Aramid fibres are cheaper than carbon
fibres, kevlar composites may be 50% less eX[lensive than carbon fibre 1'01' equal weight and thickness.

Hybrid composites containing kevlar and carbon can be used for heavily loaded structure parts and
secondary components, cabin furnishings and floors.

Kevlar has a low compressive strength which can be improved hy the addition of glass or carbon fibre in
hybrid form.

COMPOSITES AIRCRAFT ,COMPONENT

I. Boron/epoxy F-16 Horizontal/vertical tail skin.

2. Graphite/epoxy Av - 8B Wing skin, control surfaces, front fuselage,

3. Hybrid B/C epoxy. Mirage-2000 Fin, Rudder, u/c door, access door,

4. Carbon/epox y Rarale-A Front fuselage, elevons.

5. Kevlar/epoxy Nose cone, wing root fairings.

Q2.What are the techniques used for composites inspection?

Q11.Is it possible to use NDT method for inspection of composite? Explain
C;:OMPOSITE INSPECTION:

NDT used for composite are:

Acoustic Emission, Holography, Ultrasonic, X-ray, Thermo graphy, and ring test.

"Always consult the manufacturer maintenance manual for s[leeific tesling and repair procedures" as they
apply to a particular aircrart.
 I<III:C Tc'SI:

1<.111.'2lest '-',11,1be: use:d III J~IL'C'I VUlll., 1IIIIel'II.t1 L'Lld;S) bci",c'l'li till' i,l\l'I', i ;,,:,111wel~il' Illel,,1 1;IPplll."
devices is used It) tafl on Ihe bonded arc"" Ii' llil' budlll!;' II1 I;ILI, I,ll"" 1;lp!lill'.' :C1\l"; <I sulld rln)' \\Iund
I1 there ie; ,I void 01 dctaminallon undl'l' llie :;ul'I'iICC" Ih~ 1"j1I'III~ r',';u!l\ I11 dlli I :;uulld JI :"el1drd(IUII 1:-
1\)Cdled the cxtent 0" separalion has 10 bl' ev:J1u:lted by. \lIhn 111O;PL'Ciil;li,csull"

.
ULTRASONIC TESTER

Can be used to transmit a sound wave signal in to a solid lamlnalc panel, the sensor:; of Ihe analyser send
and receive the sound signal and evaluate the speed at which il moves Ihrough the structure. The Jnalyser
tllen displays the signal time on a cathode ray tube, A trained technician can evaluate the display and
c!::tcrmine the locations, depth and external of voids, delaminaiion, resin richness and starvalion and other
danlage as the sendinglreceiving probe is positioned on different parl~ of the :;tru<-:Iure.
A coupler or thin coating of pelrolculll jclly is used between the sending unit and the material
Petroleum jelly provides an airtight bo,ld between the material and the piCK up dc'"icc.

RADIOGRAPHY

Radiography can k accomplished by using X-ray signals. Tlil::;e C1111be llSt'd to locate moistur'~, and
corms ion in Honeycomb, delamination and seraration of the core fn)/J'i the skin

ACOUSTIC EMISSION:

Acoustic emission monitoring is used to detect corrosions and disbanding of adhesive bond,
This system also relics on the transmission of sound waves through a material. This inspection employs a
very sensitive microphone and amplifier. The microphone is placed on the surface of a bonded structure.
If active corrosion is present, the noise associated with the bubbles generated by the corrosion activity can
be detected as a hissing sound,
Q4.Explain in detail about the inspection and repair of composite components.
COMPOSITE REPAIR

Damage to one Laminated skin surface With no damage to the core C(]ll be repaired by the Illslallation of a
SURFACE PATCH:

I. Prior to the installation of the patch, the surface is cleaned by using MEK (Methyl Etheylyn Kerone).
2. Top coal! Under coat paint materials arc removed to expose the skin itself around the damaged area.
3, Cleaning and paint removal should be accomplished using absravies (A substance used to wear aw,IY
other substance by friction)
4 .. Chemicals for cleaning and paint removal may lead to weakening of the composite structt'.re.
5. The damaged area is either tapered using a small DISK SANDER OR MICROSTOP GRINDER to
remove each layer.
C,. The damaged area is removed with ascending concentric circles of maLenal in \/2 inch increment.
7. Circular patches of repair material are cut, corresponding to the diameter of the removed material.
~. The reflair material must be the same type as the original.
l), If 3 layers of fabric have to be cut back, then four p3tches are cut.
I () 1st ratch is the size of the material removed from the innn most porl!\)11 ul'lhe taflCl'ed area.
11. Next two patches are the size of the next two corresponding enl<:l'.'2I::1' iaycrs.
12 Fourth patch is lay enough to ov.erl:q) tile ~,lJ)lkJ Circa hy (ill': !/Ilill!1i11 Sides
[:1 A thin coal or adhesive (resin) is thcn (lpptled ol'ellhe ck~\Ilet.i ;!lld I'll'l'ilreJ ;IICI
14. P.ach patch IS saturated with adheSive.
I S. The patches Clre stacked sequenciCllly 1'1'0/11sl1l,Iikstto largest :Illci pblL'J over the JalnClgcu al·ea.
I Cl The W;trp rihrc~ of the repair pillehes l1lust ,i1ign with thc'w:lrp dll'CCIIU!lllf [he origln;!1 part material.
 -.
BLISTER
An enclosed raised spot on the surface of a finish or ~l metal.. Jt may be filled with vapour or with products
of corrosion.

DELAMINA TION
Separation of the core ancl face shcels ()f ,I hOlldecl sll·ucturc ;lloll<! a hond lille.

DENT

A depreSSion In ,\ surface usu,lily c,lllsed hy the 11,1/[ hCIIl<!slrud With an ohJect.

Q9.Describe the procedure followed to repair the moulded mat fibre glass assembly.
REPAIR TO GLASS-FIBRE LAMI~:I.ES

TEMPORARY REPAIR:

In some instances when the proper repair materi~ds are not ,\v<lilable, a temporary repair to a glass fibre
laminates may be permitted.
This may be effected by means of doped-on fabric patches or by a bolted aluminium plate. The patches or
plate should overlap the damage by at least 50 mm.

SCRATCHES OR DENTS

Scratches or dents which do not penetrate the glass fibre cloth are considered to be minor damage,should
be repaired as follows:

I. Clean the area surrounding the damage.

2. Mix a small quantity of resin ,and hardener and fill the scratches and dents to restore the original
profile.
3. Allow the resin to cure, then sand any irregularly in the surface of the repair.
4. Wash off any residue and repaint the repair to the original structure.

SMALL BLISTERS AND DELAMINA TION:

The extent of any blister or delamination of edges should be checked in order to determine whether the
damage is with in the limits for this type of repair.

Blister should have at least two small holes (0.8 mm) drilled through the separated layer close to the edge,
and mixed ('esin should be injected by means of syringe, in to the holes, until it completely fill the void.
Pressure should he ~lpplied to llattcl1 [he hlister and remove excess resin, this pressure should be maint;uned
until the resin has cure. Surplus resin should be sanded off and the paint renewed as necessary.
"').- ·,~:·.:.·:·I:··· I. \"! '~'.'("'1";f"':,·e:~·-!
Edge delamination should be thol'Oughly cleaned and 'mixed resin should be. forcedpe,t~eenthe separate
--:0~.'r.r: plies so as 10 fill the voids. Then pressure should be' applied to the damaged area, c~re being taken to
maintain the original edge profile. When the resin has cured, the excess resin shoulq be. sanded off.

Q10.Explain a typical example of the procedure used in the repair of a mat-moulden assembly.