ADVANCED COMPOSITES

 The term composites are used to describe two or more materials that are combined to form a
much stronger structure than earlier material by itself.
 The simplest composite is composed if two elements the matrix which serves as a bonding
substance and reinforcing material.
 Many times, a third element is added called core material.
ADVANTAGES

 High strength to weight ratio. (20% weight reduction is achieved when metal parts are replaced
with composite parts)
 Easily moldable into complex aerodynamically countered structures. (Reduces drag by making
smooth surfaces).
 Simplifies construction by reducing the use of fasteners and number of parts overall. (Very large
structures can be manufactured in one piece)
 Composited flex in flight without producing stress cracks like metal.

 Strength of a composite material depends on the type of fabric and bonding material used.

REINFORCING FIBERS

 They give the primary strength to the composite structure.

 Hybrids: different fibers used in combination, woven in specific pattern in combination with other
materials such as rigid forms to from an even stronger material.
I. Fiberglass: -
o made from small strands of molten silica glass which are spun together and woven
into cloth.
o Low cost and widespread availability make it most popular.
o More weight and less strength compared to other fibers.
o Polyester resin is used becomes brittle.
o There are two types of fiberglass: -
i. E-Glass: -
 Known as electric glass for its high resistivity.
 Made of borosilicate glass.

ii. S-Glass: -
 High tensile strength applications
 Magnesia-alumina-silicate glass.
II. Aramid: -
o Characterized for its yellow color, excellent tensile strength and flexibility.
 o Aramid is the name given to aromatic polyamide fibers A.K.A Kevlar.
(Dupont)
o Tensile strength of aluminum is one-fourth of Kevlar.
o Kevlar 49- Aircraft
o Kevlar 29- Boats
o Kevlar 129- Bullet proof.
o Used in high stress and vibrations region.
o Drilling aramid is a problem because the drill bit grabs a fiber and pulls until it
stretches it to the breaking point.
o It is called a fussy material because
a) It absorbs moisture
b) Because drilling is not perfect, its hard to drive in fasteners
c) Moisture will affect resin system causing it to deteriorate.

III. Carbon fiber: -

o AKA graphite
o Black in color and stiff.
o Used to fabricate primary structural components,
o Has higher compressive strength than Kevlar, but is too brittle than Kevlar.
o Corrosive when in contact with aluminum. To prevent this a layer of fiberglass is
used as a barrier between carbon fiber and aluminum.
IV. Boron: -
o It is made by depositing boron onto thin filaments of tungsten.
o 0.004-inch diameter.
o Excellent compression strength and stuffiness. And is extremely hard
V. Ceramic: -
o Used in high temperature applications.
o 2,200F
o Often used with metal matrix.

FIBER PLACEMENT
 Strength of fiber is dependent on the weave of the material.
 The tensile strength given in many books is of the fiber itself, but not with resin added.
Addition of resin decreases the tensile strength.
 To calculate tensile strength of 50% fiber and 50% resin mixture, add the tensile strength
of fibers and resin and divide by 2.

FIBER SCIENCE
 Selective placement of fibers to give the greatest amount of strength.
 The strength and stiffness depend upon the orientation of fibers

FIBER ORIENTATION
  Warp: -
o The fabric that runs the length of the
fabric as it comes off the roll
o 0°
o The material will be stronger in wrap
direction than in fill direction.
 Fill: -
o Run perpendicular to the wrap.
o 90°
o They intervein wrap
 Sleave edge: -
o A tightly woven edge produced by the
weaver to prevent raveling.
o Parallel to wrap threads.
o It is removed while use due to the
difference in weave.
 Bias: -
o 45° to the wrap
o This direction is often used for making complex shapes.

FABRIC STYLES

I. Unidirectional: -
o all major fibers run in the same direction.
o There is no fill. Small cross threads are used to hold the major fiber bundles in
place
o This kind of fiber arrangements is found in tapes. These types are mostly made of
carbon fiber and are often used in temporary repair of a part is being done.
II. Bidirectional or multi-directional: -
o Fiber runs in two or more directions.
o Usually these woven together will be seen in many different waves.
o Wrap usually have more fibers,
III. Mats: -
o Chopped fibers are compressed together to form mats.

FABRIC WEAVES
 The fabric that are in waves are more resistant to wear and corrosion than unidirectional fibers.
 Plain weave: general cloth weave
 Crowfoot stain weave: every 2 strings are up.
 8 harness stain: every 8th string is up
HYBRIDS
 Tailoring a part with different types of fabric combinations.
 Intraply hybrid: -
o Utilizes reinforcing material from two or more different fabrics.
o Final strength can be designed based on the strength of each fabric.
 Interplay hybrid: -
o Two or more layers of different reinforcing material laminated together.
o Each layer can be unidirectional or bidirectional.

MATRX MATERIAL
 Matrix is the bonding material that completely surrounds the material and transfers the stress to
the fabric.
 Resin matrix is a two-part system consisting of resin and a catalyst or hardener, which acts as a
curing agent.
 resin matrix is a type of plastic.
 Thermosets: -
o Use heat to from and set the shape permanently.
o Ones cured; the shape cannot be reformed even if heated.
o They form high strength light weight structural components.
 Thermoplastic: -
o These maybe found in overhead storage bins and non-structural applications.
o Temp. doesn’t exceed 750F
o Most common example is plexiglass which is used in windshield.
 Epoxy resin systems: -
o They are a type of thermosetting plastic.
o Well known for their outstanding adhesion(sticking), strength and resistance to moisture
and chemicals.
o Maybe used in different applications like high or low temp., rigidity, flexibility. Also,
maybe fast cured or slow cured.

WORKING WITH RESINS AND CATALYST

 It is important to mix resin properly to provide adequate strength.
 Each part of resin is weighed before mixing
 Always mix resin with hardener before mixing any fillers.
 Cold resin will whey more than room temp resin.
 Resin should always be mixed in proper ratio, mixing instructions are always provided with container.
 Mixing requirements may also be present on aircraft structural repair manual.
 Never used waxed container to mix resin. If used the wax may mix with the resin and cause incorrect
curing.
 Mix resin for 3 to 4 mins.
 Don’t mix resin too fast. If did small bubbles will rise in the air and fall on skin and eyes.
 Mix small amounts. if we mix large amounts, the large volume of hardener will cause acceleration in
the curing process and will become too thick to apply.
 Pot life: is the amount of time we have before the harder will completely harden the resin and be
unworkable.
 Shelf life: product is good in unopened container.
 Resin rich part will be too heavy and brittle
 A resin starved part will be too weak. And stresses cannot easily transfer to the fabric.
 50:50 ratio is good, however 60:40 ratio is preferred

ADHESIVES
 Some resins are used in bonding different laminations together. Called adhesives
 It comes in cans and also in film form(tape).
 Film form has resin and catalyst mixed together already. And need to be refrigerated.
 Foaming type: of adhesive is used to replace honeycomb core material. When heated the adhesive
will foam up and get into crevices.

PRE-IMPREGNATED MATERIALS
 Resin system already impregnated into fabric
 It is manufactured by dipping the fabric in resin solution.
 They are made from unidirectional material instead of woven fabric.
 They contain 50 % fabric and 50% resin. But during curing come resin is squeezed out and 60% fabric
and 40% resin remains.
 Most prepregs have to be refrigerated.
 Out-of-freezer life: time that material is actually out of freezer and is being cut or transported. This
has to be noted down
FILLERS
 Fillers are added to resin to control the viscosity and weight, to increase pot life, strength and to
makes the application of resin easier.
 Fillers are inert and will not chemically react with the resin.
 They are added only to the resin system which have been properly weighed and mixed.
 Fillers are added as percentage of mixed total resin and catalyst.
 Filler can be microbaloons, chopped fibers and flox.
 Microbaloons are small spheres of plastic or glass. Glass is more common coz the solvent action of
resin will not affect the microbaloons.
 Flox is fizzy fiber taken from fabric strands.
 Flox is added when strength is required

CORE MATERIALS
 Core material is the central member of an assembly. When bonded between two thin face sheets, it
provides a rigid light weight component. Composite structure manufactured in this manner are called
sandwich construction.
 Core material gives great deal of compressive strength to structure.
 The main core materials are foam, honeycomb, wood.
 Honeycomb has more strength-to-weight ratio but foam is more forgiving. (If form core is damaged
has memory and will return to 80% of its original strength)
 Honeycomb: -
o Shaped like a natural honeycomb. Has best strength to weight ratio.
o Maybe constructed of Al, Kevlar, carbon, fiberglass, paper, Nomex (DuPont), steel.
o They are made by crimping the core material into place, called ribbon direction.
o Honeycomb will only tear in ribbon direction.
o Honeycomb is joined together using foam adhesive.

 Forms: -
o Different types of forms are available according to structure and application.
o The advantages of sandwich construction can be shown by comparing four layers of solid
fiberglass laminate to a foam core sandwich structure that is four times thick. This part has
two layers of fiberglass on top of and two in the bottom of the form. It becomes 37% stiffer
than laminate and ten times stronger with only 6% increase in weight.
o Styrofoam:
 Used in commonly home built aircraft
 Should be used with epoxy resin only. Polyester resin will dissolve the material.
 It can be cut with hot wire cutter.
o Urethane:
 This can be used with both forms of resin.
 Cannot be cut with hot wire cutter coz of hazardous gas release.
o Poly vinyl chloride (PVC): used with both resins and can be cut with hot wire cutter.
o Strux: used in structural applications. known as cellulose acetate.
o Wood cores: balsa wood or laminated hard wood are used

MANUFACTURING
 20% reduction in cost when metal parts are replaced with composites.
 Advanced composite materials are five to ten times more costly than aluminum.
 Assembly time reduces by five to ten times if we use composites.
 Most manufactures augment the strength of composite structure by appliying heat pressure while
curing . this helps in:-
 Complete saturation of fiber material
 The pressure squeses out exes resin and eliminates air bobbles,
 Heat accelerates curing process

MANUFACTURING METHORDS
 I. Compression molding:-
o Uses a male and female mold.
o The fabric with resin or the pre peg is put on the female mold to form the shape of
the part.
o If core material is used, the fabric is wrapped around the core material and put in
the mold.
o Heat is applied on the mold to cure. (hot oil or electrically heated)
II. Vacuum bagging:-
o The component is placed in plastic bag and air is pumped out using vacuum pump.
Pressure is applied by the surrounding atmosphere.
o 28 inches of Hg
o Can be used in combination with molds, wet layup and autoclave curing.
o Very uniform pressure applied
III. Filament winding:
o The reinforcing fiber is wound as a coetaneous thread around a desired shaped
mandrel.
o Many use pre preg threads or the fiber is dipped in resin.
o Ones laid, structure is cured
o Used to fabricate helicopter rotor blades, propellers.
IV. wet layup:
o less precise.
o Mixing fiber with rein and laying it wet on a surface.
o Methodology associated with wet layup is the same as composite repair.
V. Lightning protection:-
o Aircraft needs to have electrical contact between panels to prevent arcing and
electrical damage.
o Aluminum is used to provide this conductivity.
o Electrical bonding:-
 Al wires may be woven into top layer of composite fabric.
 Fine Al screen is laminated under top layer(used in carbon fiber).
 Molten aluminum maybe sprayed like paint.
VI. Painting of composite structure:-
o Boeing used tedlar on composite before painting. It is a plastic coating which
serves as additional moisture barrier.
o Gel coats:-
 It is a polyester resin which is used during the manufacturing of part.
 Manufacturing mold is laid with color coating. This is transferred on the
structure by the end of curing.
 They are strong and flexible, and if stored in sun, they might crack .
o Paints:-
 Primer should be applied before paint.
 Adds weight to the component.
APPLIYING PRESSURE
 Vacuum bag is the most common form of applying pressure.
 Shot bags:
o Used on large components that cannot be clamped.
o It is like a big bean bag
 Clecos:
o Used in conjunction with caul plates to support back side of the repair.
 Spring clamps
 Peel ply:-
o Nylon fabric used in vacuum bagging process to make sure the fabric doesn’t stick to the bag
 Vacuum bagging:-
o Vacuum bagging is the only curing method that should be used in high humidity areas because
this process evacuates air.
o Bleeder: used to absorb exes’ resin.
o self-enclosed bagging can be used on parts when they are removed from the aircrafts. They
should not be used on hollow parts. It is a plastic bag in which the part for curing is kept.

VACUUM BAGGING PROCESS

 the layer immediately after the resin and fiber mixture is the peel ply also called parting film .. used to
make sure the vacuum bag doesn’t stick to the fabric.
 The peel ply is porus and allows the exes resin to flow though it to the bleeder.
 A bleeder is an absorbant material placed to absorb exes matrix.
 A breather is placed on one side of repair to allow flow of air through it to the vacuum valve.
 Breather and bleeder are in most cases made of same material.
 A vacuum valve is placed on breather which is connected to a vacuum hose.
 A sealant tape is used to maintain low pressure inside.
 If a heat blanket is used, a parting film should be placed below the heat blanket to prevent it from
sticking to the surface.
 Vacuum bagging films are laid on edges of work.. they r made of nylon
 Leak check should be performed.
 The rough surface of peel ply allows the paint to stick.

METHORDS OF CURING
 The curing process can be accelerated by the use of heat.
 Room temperature curing:-
 Full cure strength is not achieved until five to seven days.
 Usually performed in areas where the operating temperature is low.
 Used in lightly loaded and non-structural parts.
 Heat curing:-
 Resins need elevated temp during their cure in order to devolup full strength and reduce the
brittleness of cured resin.
 When a part is manufactured at high temperature, the repair work should be done at approx..
250 to 750F
  If too much heat is applied, the matrix wil start gassing and small bubbles are formed on the
surface.
 After curing it is very important to monitor the cure rate.

 Step curing:-
 used when manually operated controller is used.
 Requires the technician to make adjustments to the temprerature at regular intervals.
 It is a process of rising and decresing the remp slowly. Temperature is increased and then hold
for some time. This inc in temperature in continued till cure temperature is achived. Same is
followed while cooling.
 Slow cooling gives stronger final cure.
 Ramp and Soak Curing:-
 Done in programable controller.
 Heat or cools a repair in a specific rate.
 The cure temperature should be hold for some time which will be specified on structural
repaur manual.

HEATING EQUIPMENT
 Heat lamps
 Heat guns:- a typical heat gun can generate temp of 500 to 750F.
 Oven .
 Autoclaves: very big oven
 Heat blanket

MACHINING COMPOSITES
 Cutting uncured fabric:-
 Scissors with special blades with serrated edge are used to cut through aramid.
 Ceramic blades are also available to cut aramid.
 a conventional scissor is not used to cut aramid because the edges will hold the fabric.
 A conventional scissors will saperate the weave.
 A pre preg can be cut using a razor blade or a utility knife.
 Machining cured composites:-
 Cutting fluids are used.
 If wrong type of cutting fluid is used, composite wont cure properly.
 Toxic fumes are generated when working with cured composites.
 Drilling and countersinking:-
 Delamination, fracture, breakout and saperation are common types of damage due to
improper drilling.
 Material should be backed with wood to prevent these problems.
 Use an extremely sharp drill bit
 Do not use coolant oil during drilling in any sandwich construction.
 Carbide tip
 Dimond dust cutters should only be used with fiber glass and carbon fiber.
 Use as high speed as possible
  Included angle:135°
 Drilling aramid:-
 Due to its flexibility, a conventional drill bit will pull the aramid to a point of breaking thereby
damaging the whole composite laminate.
 Brad point drill bit. Is specially made to drill aramid
 It tends to absorb moisture. So make sure you seal the walls of the hole with resin.
 Weight of the drill machine is sufficient. No need to apply extra pressure. Make sure high speed
is there.
 Will show smaller diameter.
 drilling carbon fiber or fiberglass:-
 can be done with conventional tools.
 Carbide tip is preferred for longer life of drill bit.
 Carbon dust is dangerous and flammable. Make sure you use a respirator whole working.
 Generally will show larger diameter.
 Dagger or spade drill is used for these materials.
 All fasteners are made of CRS or titanium .
 Sanding is used to remove single layer of fiber at a time. Widely used during repair
 240 grit sandpaper is used.
 Routers:-
 Operate at 25k to 30k RPM.
 Used for rooting or removing damaged core material.

ASSESSMENT AND REPAIR

TYPES OF DAMAGE

1. Cosmetic defects:-
 Damage only of outer skin.
 Chipping or scratching of outer skin.
2. Impact damage:-
 Struck by foreign objects.
 Caused by careless handling during transport.
 Nicking, chipping, cracking or breaking away.
3. Delamination:-
 Peeling of layers of laminate.
 Compound problem, no specific cause.
 Direct replacement of the part.
4. Cracks
5. Hole damage

INSPECTION METHADOLOGY
 1. Visual inspection: no removal of component.
2. Coin taping:- damage is identified by sound.
3. Ultrasonic inspection
4. Thermography
5. Laser holography
6. Radiography
7. Dye penetrant

REPAIR METHADOLOGY

1. Determine damage: using methods shown above

2. Surface prep:-
 Removal of paint
 Also called stripping the laminate
3. Removal of core damage: using router
4. Laminate step cutting and scarfing.
 Each step is ½ inch long.
 Scarfing: making a slope
5. Cleaning
6. Water break test: used to check contamination of surface oil.
7. Removal of water from damaged area
8. Laying up and curing.

TYPES OF REPAIR

1. Mechanically fastened pre preg patch.

2. Potted repair
3. Delamination: resin is injected into the void created.