Composite Materials for UAV

structures and Fabrication

Methodologies

by

Shashank Sharma
Composite material components for UAV
manufacturing:
• Carbon Fiber
• Kevlar
• Epoxy
• Basalt
• Fibre Glass
Carbon Fiber

• Because of the manufacturing technology currently in use, carbon

polymers(turbostatic) are susceptible to flaws in their grain structure.
• Weibull material strength statistics dictate that Carbon be manufactured in fibrous
form to reduce the chances of failure due to flaws in grain structure.
• Fiber manufacturing involves processes such as spinning, thus enhancing
directional characteristics of the grain structure.
• Manipulation of directional characteristics is possible.
Carbon Fiber:
Properties

• High Tensile Strength(3.5 GPa)

• High Stiffness (234 GPa)
• High Shear Modulus(10-15 GPa)
• Low Shear strength
• High heat tolerance
• Low Failure Strain(2-5%)
• Types: Turbostatic, Graphitic
Epoxy resin
Epoxy Resin
Applications

• This is used as the matrix material for carbon fibers because of it’s high
viscosity, boosting impact strength of the composite.
• High adhesive and cohesive strength reduces the chance of slippage
between fiber-matrix interface.
• High compressive strength(2-3X more than concrete) reduces the chances
of fiber buckling.
• Low thermal conductivity reduces localized breakdown of grain structure in
fibers.
• Low electric conductivity reduces chances of electronic interference with
electric components.
Carbon-Epoxy Composite
Carbon/Epoxy Composite
Application

• Usage in wings: In the form of spars,

skin, stringers.
• Usage in fuselage: In longerons,
stringers, stiffeners, in the
empennage.
• Used semi-monocoque General
Aviation aircraft.
Kevlar
Properties

• Higher tensile modulus than steel wire

• High breaking tenacity
• Very high impact strength
• 4-5-times strength than steel
• It has a much higher tensile modulus than steel
wire
• Sensitive to environment.
• Low compressive strength
Kevlar
Applications

• High strength retention in a wide temp. range

enables it’s use in cryogenic systems (i.e.
rockets).
• Impact strength enables for use in armor
plating aircraft.
• Presence of hydrogen bond means, this
material is sensitive to environmental factor,
usage of epoxy resin as matrix reduces this
threat.
• Drilling, once applied to a surface is only
possible with especially made drill bits.
• Very high cost w.r.t carbon fiber reduces usage
in most places.
Basalt Fiber
Properties

• Good Mechanical Properties

• Acid-Alkali Resistance
• High Wave Permeability
• High abrasive hardness
• Excellent Sound Insulation
• Acoustic Insulation
Basalt/Epoxy composite:
Applications

• Used in high temperature environments.

• Acoustic insulation for passenger aircraft
• Vibration absorption for rotorcraft as well as aircraft.
• Usability in abrasion-intensive applications
FIBER GLASS(S-Glass)
• High Tensile Strength(4.7-4.8 GPa)
• High Compressive strength(4-5 GPa)
• High Thermal Endurance
• Good Impact Resistance
• High Electrical Resistance
• Good Thermal Properties
• High chemical resistance
• Harmful for respiratory tract
• High crack propagation
Fiber Glass
Applications

• Interior of Passenger aircraft

• Reinforcement for unidirectional carbon fiber, since it becomes a
cheaper alternative.
• Used as radome structure for aircraft/UAV Radar,VHF and GPS
antenna
• Good mouldability allows for usage in design of winglets in UAVs and
Passenger airliners.
 Composite Fabrication methods

• Vacuum Layup
• Hand Layup
• Resin Infused Molding
Vacuum Layup
Hand Layup
Resin Infused Molding
Thank you