[DOCUMENT TITLE]

MECHANICAL ENGINEERING DEPARTMENT

Aerospace engineering

AERO 395

COMPOSITE MATERIALS
REPORT BY:
GROUP 8
09/02/2023
LECTURER: DR. (MRS) EUNICE A. ADJEI
Introduction
Composite materials have become the order of the day when it comes to the aerospace industry.
Due to its toughness, light weight, corrosion-resistant and also its ability to be drawn into and
shape, aerospace engineers are gradually replacing the metallic components with composite
materials. For example, fiberglass.

Theory

Polymers-It is made up of monomer of identical forms.

It occurs naturally and synthetically

Fiberglass

It is mixed with resin and casted. It is casted in layers.

Catalyst/Promoter

It is used to speed up the curing process. Cobalt accelerator or MEKP is used. Catalyst methyl
ethyl ketone peroxide (MEKP) is added to Resin, Gelcoat or Flocoat to create a chemical
reaction producing heat that cures or hardens the resin. In an ideal situation catalyst MEKP is
added at 2% based on volume. However, in cooler temperatures or if you want a faster curing
time, a higher rate can be added (3%). In hotter temperatures, a lower rate can be added in order
to slow down the curing process (1%). For a normal 2% example, if you had 500ml of resin, you
would add 10ml of catalyst MEKP.

Hardener

Epoxy Resin Hardener is a curing agent used in conjunction with West Epoxy Resin at a ratio of
five-parts resin and one-part hardener.  It cures slowly at room temperature, so it is ideal for
larger projects or for using in warmer temperatures.
Resin

Fiberglass resins are essentially polyester resins, and they are used for many different purposes.
They are mainly used as a casting material, a wood filling, an adhesive, and for auto repairs. It
holds the composite materials and also it helps to distribute mechanical load throughout the part.

Advantages of resin

1. It cures easily
2. It is easy to use
3. It is less expensive
4. It does not drip fast
5. It is resistant to corrosion
6. It is tough

Disadvantages of resin

1. It has short shelf life (3 months)

Epoxy

1. It cures quickly so it is used for marine application

2. It requires only hardener to cure rather than a catalyst.

Advantages of fiberglass

1. It could be easily be moulded into any shape

2. It has mechanical strength that is so strong and stiff for its weight that it can out-perform
most of the other materials.
3. Fibreglass last a long time
4. It can be coloured, shiny or dull.
5. It is low maintenance
6. It is anti-magnetic
7. It is fire resistant,
8. It is a good electrical insulator and weatherproof.
9. It is relatively light in weight
Disadvantages of fiberglass

1. It needs to be re-gel coated about every five years

2. It can result in airborne fibres which may be an issue to asthmatic patients.
3. It requires Gaps around down lights
4. Electric boxes reduces its effectiveness
5. It loses its effectiveness if Insulation becomes wet or damp and irritation during
installation.

Uses of fiberglass

1. The resin is lightweight and is therefore excellent for use in aircraft. The body panels of
cars, planes, and boats also use fiberglass resins.
2. Breweries use fiberglass grating for bottling liner.
3. Docks and marinas also use fiberglass as a protective barrier from corrosion and rust
from the natural elements. The implementation of fiberglass helped the boat industry
tremendously due to the cost effectiveness of fiberglass materials.
4. These positives surrounding fiberglass are also found in the cooling tower industry.
Cooling towers tend to be moist areas that need protection from rust and corrosion. This
versatile product is also used as screening to mark off dangerous areas.
5. Food industries also benefit from the properties of fiberglass as they use the material to
hold up corrosive blood in chicken and beef plants. Etc.

Experiment

Apparatus

 Mould
  Mixing container
 Stirring rod
 Brush

Materials

 Fiberglass
 Resin
 Hardner
 Catalyst
 Oil
 POP

Procedure

 The inside of the mould was smeared with oil to prevent the cast from clinging to the
walls of the mould.
 The quantity of the resin that was needed for the work was poured into the mixing
container
 A proportional amount of catalyst was added to the resin and stirred very well.
 POP was added to the mixture and stirred very well to give the mould an opaque look
 A proportional quantity of the hardener was added and stirred very well
 Portion of the mixture was poured into the mould to give serve as the first coat.
 The fibreglass was then spread on the walls of the mould where the first coat of resin was
poured.
 The remainder of the mixture was then poured on the first layer to give a second
coat/layer.
 It was left to dry/cure.

Health and safety

1. Wear protective clothing

 2. Work in an airy place
3. Wear gloves
4. Wear eye goggles
5. Wear steel toe boots
6. Use a separating agent such as shea butter
7. Wear a nose mask

References

1. https://industrytoday.com/article/top-uses-of-fiberglass/
2. https://sites.google.com/site/thekacassite/fibre/what-are-the-advantages-and-
disadvantages-of-fibreglass
3. Notes from the Department of Sculpture of Kwame Nkrumah University of Science and
Technology, Kumasi.