- “srlockheed P.O. 60x 748, For Wort, Texas 76101 DESIGN AND MATERIALS HANDBOOK FZM- 6374 (PART I ~ DESIGN MANUAL) Prapared and Issued by ENGINEERING DEPARTMENTSNES DESIGN MANUAL | sme coco PEE SecTION 2 ADVANCED COMPOSITES TABLE oF coMTEsTs PARAGRAPYL me Lo Generat 20 wet 3.0 Manufacturing Capacity wet 3.0 design crizerta ur, aa Laninace Orientacion wa 4.2” mtckness wa as surface Treatment 3 aa Jotnes w8 3.0 F-16 Advance Composite Components wer 6.0 Specification and Reference Sources va List oF Frouaes EIGURE um PAGE wt Ply Guanctey and Direction Code . 12 7-2 Symmetrical Balanced Layup 1-2 wea Panel Taper 3 Forner Fabsteated by Urapping and Draping Material over a Mandret wre Former - Fabricated by Draping Material Over a andre! wes Bend Radif for Advance Conposizes 15 muletple Step Sonded Lap Joine ins que Requirements for Threaded Fasceners y F-16 Graphite-Epoxy Structural Componente u REVISION re |REVISION sowceo comosines | vmmenas owamies = DESIGN MANUAL secttoy 1? ADVANCED COMPOSITES 2.0 GENERAL ‘tais section discusses the various desiga concepes ucilizing high-serengch, highenodulus pete seer to" Saticsoua Filamence embedded ina conpacible matrix, These sacerials are classified ap "Advanced Conposices' considerable develooment and testing of advanced composites has been accerriished in-house se ieee eae ener guciiicies. ‘The filamenes most commonly used in advances ce=sosite are ets ace boron, borate (silicone-carbide-coated boron), and graphice. | Osher fibers sereeetees a faciue sapphire whiskers, silicon carbide fibers, and uitrechish-sodulus graphite Fibers the organic macrix resina mose comonly used are modifies epoxy reins develozes speciticsily FSS SREETSC.Sese. Ocner creanie resins red are polyimices anc phenolics. Aluninw= alley Ektcins ave che only mecal matrixes commercially availed; Ll The advanced coaposice materials discussed herein are uniaxial in cher sine Jince, having wery Bigh mechanical properties along thetr longitudinal axis. and tov propercies along ches transverse axis 2.0 MATERIAL SELECTION For each engineering project, see the applicable engineering materials eno for the approved advanced comporize saterial 2.1 For the F-16 program, graphite Eiber-epoxy resin impregnared per specifics! FiS-2023, was selected for several scructural components. Reference Figure 17-5 2.2 For the tape Laying machine, graphite-epoxy material {2 currently being fe che fore of a d inch wide tape consisting of parallel graphice filasencs + BE thagy resin. zach ply of graphite-epoxy is fabricated by laying adjacent $7 Sr required to obeain the area and shape desired. 7 ips of cape 2.3 For hand-leyup, 3 or 6 inch wide preispregnated cape is used 3.0 MANUFACTURING CAPACITY 5.1 The maximus size advanced conposite components chat may be fabricared (as of this dace) Scents Eactlicy is established by available equipmenc noced as follows (a) Contac 100 rumericatty concrolled 3 axis cape Laying machine. The bed seen ey ta ge 4350 inches. The maximum vertical travel is 2.37 snches the cape wadeh 1s 3.00 Laches e Aucoclave, capacity ts 10 fe x 33 fe, See Figure A FOCLAVE INSIDE SEVER 15 10 F NOTE: The dimensional Linits on the size of "hand lay-up! Advance composite compo feats ie the autoclave _/oTHE BED OF THE NOTE: As of che dare of publ "TOCLAVE DOLLY sacion ane tape laying SOS Sachine {a under procure SS Sent which will have che 7 + Capability of Laving 6 LOR 2EF Sneh wide cape Ge 3.2 Experience has revealed chat che sachine laid Laminates are superior in quality to 2 se prodused by hand lay-up. especially in chicknesses greater chan 40 plies 4,0. DESIGN CRITERIA 41 Laminate Ortencacion on lavout drawings used within che engineering deparcment, # simple code designating che number and direceion of plige is recommenced as shown in Figure 17-2 GENERAL OYNAMICS Fort Worth DivisionADVANCED conPosiTES: Seimenouser "= DESIGN MANUAL URE PLY QUANTITY AND DIRECTION CODE he rero, 445° and 90° angles shown in Figure 17-1 were chosen arbiesariy ig drawings (production, development, cest, etc.), co be veleased for sant Faccuring advanced conposire componenc(s), the layup sequence and filamenc direction of each 31y shall be specified either by note or tabulated chart on the face of the drawin 4.1.2 To minimize warpage and residual internal stresses, balance che ply orientation, in exch panel, symmetrically about the panel midplane (eenterling, Reference Figure 17-2 FIGURE 17-2 SVIOETRICAL BALANCED LATUP = (4/2/2/2) 4.1.3 The recomended tolerance on the angular orientation of filament is $5° 4.1.4 The dizeceion(s) and type of che applied Load(s) will deternine the angular oriencazion of the €ilamence in each ply. IE the design requizenent ie simply co provide axial strength or stiffness, che sajority of = aacerial (filanents) should be un‘direcefonally oriented. A noninal ancunt of transverse rel: Torcenent should be provided for scability for any off-axis loading that may occur, either cut fabrication or in service If shear loading or shear stiffness is che primary desiga consideration, chen most of che sac ould be oriented ar 215° co che Longituainel axis, as this provides che highest shear prope: Rovever, care must be taken to evaluace any Loading in the longitudinal ov eransverte. siree since the serengeh in these direccions is quite low, Conditions vhich would not normally se Exttical in metal design aay approach or exceed che screngchs available in these directions © using @ purg” tu" lgvup. This consideration may necessitate the inclusion of s sulficiens number of O° and/or 90° laninae. GENERAL OYWaMIcS Fort Worth Division REVISIONRevision Fa-o37 Page 17-3 Date Februa! “Ls From a fabelcation viewpoine, che primary difference between advanced composites nd scldacisgalaecel materiale, io chee sarte ace formed clese co che fins! configuracion elininacing Suen of che sachining and all the ferming A.1.6. Each advanced composite component should be desigréd so char it will not lock ieseLf on 4.2. THICKNESS magnitude of load(s) and/or the required structural stiffness will determine che sunber (a) Exterior skins are .020 in. (use sinimum of 4 plys) Ge) Interior skins are .015 in, (use sinimun of 3 plys) NOTE: Per FUS-2023 graphite-epony: 4 plys equals .022 in. chick aed 3plys equals O17 in. chick. 4.2.3 There is ad recomended aaxisum chickness. Panels in excess of 100 plies have been fabric dad euree successfully (0550 Ln. chick ref) 4.2.3.1 tantnaces in excess of 40 plies require careful process development to assure chat che Sooliag anc eure eyele will produce acceptable quality comonencs 4.2.4 Talekness of FUS-2023 graphite-epoxy afcer curing is .0055 t .0003 in per oly d.t.5 che lrectional nature of composite laminae provides the abiltey co conscruct s aacersal Saheb EET SESSRSSEAC ISU. dndvor seittness requirenencs vith a einimm anount of wacerial and SEISRS'S idecdlas serengch and eciffness only where needed. Typéeal panel tapers are accoop ished SPR ar Te i kadtpanete as shown in Pgure 17-3. shen locating capered areas, che effect on the ving serfaces of the adjacene supporting structure should be considered. 10 wawrea PER PLY (20 MIST 2 PLIES REF) ‘KEEP CONSTANT TK EACH GROUP OF PLY ENDS. Sean FIGURE 17-3 PANEL TAPER 2.2 SURFACE TREATIENT “oS.t A protective resin impregnaced glass fabric eurface ply may be provided for exterior qalse tlie Sifdace: of advanced composite assemblies hich are exposec co the airstream. This Subfece sly aay also be used for ocher spplicacions where sin danage is a possibility ietigsache’ glace fabric surface ply 1s fabrieaced as a parc of the decail The resin 4.3.2 Peel plies wich are not cecained af pare of che finished ites are not specified on Gelidagst labgoltenence for the nylon peel ply used on surfaces co be painted and surfaces which ravings: Meese peeded to another surface will be established by a referenced process specification 4.3.3. Galvanic Corrosion ‘ang boron materials are classed "Group IV" where as aluminum alloys are in “Group T sng Renee MIL erb-889, To prevent gaivanic corrosion of the dissintlar caterials ac and Tying surfaces of the joints, insulatign shail be provided. Class-fabric or plastic (Liquid Shic) are acceptable insulators ‘Fort Worth Dvsion aovaNcED conPosrTes senenesccemes DESIGN mawuat |Pe37s ApvauiceD composites | Page 1? famenowee "= DESIGN MANUAL Date February 1975 4.3.3.1 On assess swings for advanced composite components char also utilize alunirun alloy conponence, s2ecia: inscructions (a noce on ehe draving will suffice) are needed to insure che Senoval of ai: grasnice or (boron) machining residue on completion to preven: corrosion. 4.3.3.2 Seal 411 alucinum alloy component faying surf machining resise’ cel to prevent entrapment of graphice extton(s) 4.3.4 For she reguired prime and finish coatings, see che applicable finish spec for each progras involved, 66 sors: Advanced conposices have che pocential co produce a weight saving of over 50 percent of che Siruccural sesgat of a vehicle, Because of praccical constraints, however, only a 30-percent feduecion <2 ily realized, One of the ajor constraints is encountered in che area of An advanced corposize scructure is a composition of materials consisting of high-scrength, Righ- sSedeed in a matrix vnoss primary functions are co furnish scabilicy co the fibers fo aveid or at Lease Mollify areas of stress concencracion Joints, which cuss be present when any two conpenents are assembled, are 2 major source of stress existing equirse Of joining rec ising che capacity of the the nuaber of joincs be kepe co 2 minimum by ses are available. Thay are referred €o herein a5 bonded and Gechanical joints 4.6.1 BONDED semTs Bonding of forcers. Eranes, longerons, stiffeners, or stringers, ete. co skins (weds, ete.), may be accomplished a+ follows () The forcer cacerial ts draped over the mandrel or form chac creaces che former shape The adn and forwer(a) axe then cured cogecher, Reference Figure 17-5. (2) An alcernace approach is to wrap half che plies of former sacerial around the mandrel(s) {Sores the Former shape. Position the wrapped manérel(s) on the (uncured) skin Drape che second half of the former material over the wrapped mandrel(s), The skin and forner(a) are then cured together, Reference Figure 17-6 (3) Cured satin ds utilized with material for formers draped over sandrel(s) as ourlined in Pare. . and/or 2, The assembly (skin and formers) are chen processed chrough che cure (4) Prevesred fomer(a) are secondary bonded to pre-cured skin sc results indicated che co-cured assenblies (Ref. Para 1 & 2) ave Stuceurally superior co che pre-cured and secondary bonded assemblies ef Pare 6) WRAP AROUND MATERIAL (MINIMUM 2 PLIES) MANDREL REF DRAPED MATERIAL (HINTMM 2 PLIES) GORE 17-4 FORGER - FABRICATED BY WRAPPING AND DRAPING YATERIAL OVER A MANDREL ain conpacability with agjacent structures. Because of che nonhomogeneity cay fabricating Lacge size couponenes, Reference Paragraph 3.0. Two broad classesREVISION berate sovssceD cox genenacovnamcs DESIGN MANUAL Date February 1979 NATERTAL DRAPED YANDREL REF sexw FIGERE {7-5 FORMER - FABRICATED BY DRAPING MATERIAL OVER A MANDREL erst PARALLEL TO R = i\ som. 2 an +] “sononveroxy ian | (i Los ax. x xa fii Stet eeore 06 tw, ec S0RON/EROXY OR GRAPHITE/ EPOXY {6 BEND RADII FOR ADVANCE COMPOSITES (PRIOR TO CURING) 4.4.1.1 Highly loaded primary scracture adhesively bonéed joints are noc recomended unless they ave supplenenced with cecnanical fasteners, Test program results revealed highly loaded bonded Joints are normally critscal in fatigue and chat the analytical sechodology is noc adequate to design chis type of Joint wich adequate consideration of repeated Load and environmental effects This 'Tecomentation dees not necessarily apply to laminates designed principally for stiffness (Elucter of serodynanie benefits) and with low Leading. 4.4.1.2 Seep lap Joins are to be avoided because of the inherent difficulty in maincaining reliable manufacturing quality and the inadequacy for current NDT methods. See Figure 17-7 for Eypieal step fore avoided, ADHESIVE BOND Z GRAPHITE LAMINATES seraL IGCRE 17-7 MULTIPLE STEP BONDED LAP JOENT OTE: ENDESTRABLE FOR MANUFACTURING AND CURRENT NDI METHODS 44,2, Mechanteat Joints asceners for advanceé composites are “threaded fasteners” and permanent én Seetion 4, Paragraph 1.0, of chis manual. Acceptable sechanica Cype fasceners as descr: Fesceners should be selected from the approved parts selection List assigned co the program {nvolved. Selece fascener materials chat will noe creace adverse corrosion effects when Gissiatlar maceriais are involved, Reference Paragvaph 43-3. GENERAL DYNAMICSFamesvs Date generac ovnames DESIGN MANUAL = ne cane 4.4.2.1 Design considerations for mechanical fastened joines in advanced composites are similar Co thoae in cerventionel setallie mechanseally fastened Souncs. The notable exceptions are (1) A minimus of 2.5D edge distance is required. 2. (2) The mintoum apacing of fasteners is 4. D (center to center) for threaded fasteners ia shown fn Figure 17-8 (3) The maximus recomended corque CAUTION: Excessive corque cay cause failure by delamination of advanced conzosices, GRAPHITE LAMINATES — ee TORQUE PER ‘¢ ‘TORQUE PER NOLE CODE AS REQUIRED reTaL (2PL) L sastexer eoce pistance = 205 x FASTESER DIA FIGURE 17-8 TORQUE REQUIRENENTS FOR THREADED FASTENERS EXSTALLED IN GRAPHITE-ZPOKY COMPONENTS 4.4.2.2 The accepted method of producing holes for fasteners in composites is cutting the fibers Sad auceix by sachining the seracghe shank portion with # comon fluced érill bie and councer- Sinking with a dianond edged reaner, A procedure for solding holes, elisinacing cutting the fibers, has been developed. To-dace chis Grocedure has noe been uriliced on components in production. Molded holes are fabricated as follows the fibers are deflecced enough t9 fore a rough hole, the this aole is inserted as a agve dfe. The wneur fibers are fener head and shank as che laminate is cured the prepreg stati fastener to be used solded around the fi 4.4.2.3 On threaded fasteners, inscalled in advanced composites, chat will be renoved and fetnscalled periodically for aircrafe servicing and/or aaintenance, the fastener holes in che Ecvenced composite conponente sur: be reinforced with metal gromers Lo ganana. oynamcs Panes aa REVISIONREVISION FIM-6376 Page 17-7 Date February 1979] ADVANCED COMPOSITES 5.0 F-16 ADVANCE COMPOSITE COMPONENTS ‘A brief sumary of graphice-epoxy primary structural components for the Fr16 are tabulated in Figure 17-9 CAPRTTE TEXT ASST 1 PART 40, PART 0, i REMARKS : er7226 er7210 Geaphite-Epoxy skine varies froa 20 co 80 | Skin-Vertical plies. The skins are wechanicaily attached | Stabilizer fo aluminum alloy under-scructure consisting | Box spars and ribs ete. 1617307 1617303 Graphite-epoxy skins varies from 4 to 14 |) Scin-Rudder Rudder-Assy plies, The rudder ie 4 one-piece bonded Sandwich panel with alusinum core, spar ané | foot rib. A glass cloth ply isolate: the | graphite sking froa che aluminum core. aer7272 rer7271 Geaphite-epoxy skins varies from 4 co 8 Skin-Vere Vere Seab plies, The leading edge is a one piece Stab LE LE Assy bonded sandwich panel with alusinum core and graphite skins spar and ribs. A glass cloth) fly isolates che graphite skins ffon the | ‘uminen core. aer7ais aer7402 Graphice-epony akine varies from 5 to 52 Skin-dorizontal Horizonest Siles. Each Horizontal seabilizer is a one Stabilizer Stabilizer Piece bonded assembly vith alusinum core and aay Eip rib, titanium ribs, spar, and pivor shaft The aluminum core le igoleced from che Graphite skin with glass cloth FIGURE 17-9 F-16 GRAPHITE-EPOXY STRUCTURAL COMPONENTS 6.0 SPECIFICATION AND REFERENCE SOURCES ‘The folloving Listed specifications and references contain applicable requirements and data per~ Tinent to the design of graphite-epoxy components for military weapons syscens F5-2021 Process specification for the manufacture of laninates using FMS-2023 praphice-epoxy macerial F¥s-2023 Graphite fiber-high censile strength, intermediate sodulus, epoxy or modified epoxy resin impregnated. ¥PS-3507_ Fatigue and fracture control and ganufacturing specification for F-16 part 1677226 (ekin, vertical stabilizer box) ¥PS-4508 Fatigue and fracture control and manufacturing specification for F-16 parc LGTTAIG (akin, horizoncal stabilizer) “advanced Composites Design Guide" by Los Angeles Division of Rockwell International Corp. (Ref Air Force Material Laboratory, MPAFE Ohio, Contract No. F33615-71-C-1362) AFFDL-TR-77-67 "Advanced Development of Conceptual Harévare for the Lightweight Fighter" by General Dynanies Corp, Fort Worth Division. GENERAL DYNAMICS Fort Worth Division Simone == DESIGN MANUAL