Materials Module 3

AIRCRAFT ENGINEERING
MATERIALS
AIRCRAFT NON – METALLIC MATERIALS
07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA PPT1.1

MODULE OBJECTIVE
07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA PPT 1. 2

INTERMEDIATE OBJECTIVES

POLYMERS
– Thermoplastics
– Thermosets
– Elastomers

Classification of polymers
• Thermoplastics - reversible in phase by heating and

cooling. Solid phase at room temperature and liquid
phase at elevated temperature.
• Thermosets - irreversible in phase by heating and
cooling. Change to liquid phase when heated, then follow
with an irreversible exothermic chemical reaction.
Remain in solid phase subsequently.
• Elastomers - Rubbers

Properties of plastics
• They are resistant to corrosion

• They have a fairly low relative density.
• The strength of plastics is less than that of metals.
• Their strength decreases rapidly as the temperature
rises.
• Can be coloured if required. Some are transparent.

Composites in Aviation
– What are composites?
• Combinations of different materials which yield a
product with superior properties
• Composite armor used by the Greeks in antiquitiy
–(
http://www.youtube.com/watch?v=Aznz9mj5grA
)
• Modern composites, or advanced composites are
typically fiber reinforced plastics.
07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 7

Fiber Reinforced Plastic (FRP)
Composites
• Consists of at least two materials
– Plastic which binds the fibers together, also called the
matrix
– Fibers, typically small in diameter and long in length
• Fibers may also be short in length to facilitate
processing – e.g., injection molded nylon with
glass fibers
– In general the matrix imparts toughness, or crack
resistance, and the fiber imparts ultimate strength

Fiber Reinforced Plastic Composites,
contd.
Fibers
Plastic Matrix

Function of the Fiber
• Carry the load
– 70 to 90% of load carried by fibers
• Provide structural properties to the composite
– Stiffness
– Strength
– Thermal stability
• Provide electrical conductivity or insulation
copyright J. Anderson, 2008

Function of the Matrix
• Binds the fibers together
• Provides rigidity and shape to the structure
• Isolates fibers to slow crack propagation
• Surface quality
• Corrosion and wear protection for fibers

Relative Strength of Fiber and Matrix
Note that for the same level of

Carbon stress, the fiber deforms much less
Fiber than the resin.
This leads to the composite material
being much stronger in the direction
of the fiber. If the fibers are
Stress
unidirectional (all in the same

Polyester Resin direction) the composite material is
strong in the direction of the fibers,
but weak in the directions
Strain perpendicular to the fibers.
We can alleviate this by adding
multiple plies laid with the fiber
direction different.
Varying Fiber Direction in Plies
Varying fiber direction

in plies builds a
laminate structure with
strength in more than
one direction

Commercial Fiber
Fibers are available as
• Yarn – a bundle of fibers twisted together
– Tow - Large bundles (Carbon Fiber), several thousand
fibers
– Roving - Large bundles (Fiber Glass)
• Uni-directional tape
• Woven fabric or mat

Material Configurations

07/09/23 courtesyAME NIGERIAN
Ten Cate AvdancedCOLLEGE
CompositesOF AVIATION TECHNOLOGY, ZARIA 15
Composite Fiber Materials
• Common Fibers Used in Composites
– Glass, or fiberglass
• Starts as a silica sand
– Carbon
• Starts as a polyacrylonitrile fiber
- Aramid fibre

Fibre orientation

Types of Plastics used in
Composites
Plastics are polymer materials, that is to say that they

are made up of long chain molecules. There are two
types of plastics based on how these molecules are
bonded together.
•Thermoplastics
•Thermoplastics can be melted and re-solidified
when cooled.
• Thermosets
• Start out as liquids or paste-like solids and
become rigid when cured. Thermosets can’t be
re-melted once cured.
Common Thermoset Plastics used in
High Performance Composites
• Thermosets
– Epoxy
– Polyester
– Phenolics
– Cyanate Esters
– Bismaleimide (BMI)
– Polyimide
• Thermoplastics
– Nylon
– Polyetheretherketone (PEEK)

Aluminum vs. Composites
Aluminum is an “isotropic material”, which means it

has the same properties in all directions.
Composites are “anisotropic” which means they
have different properties depending on the direction of the
fibers vs. the direction of the applied loading.
•Composites are built in layers called ply’s that are
stacked “laid-up” to form a laminate.
•Each layer has fibers that run in defined
directions.
•Because of the layers the properties are different
“in-plane” vs. “through the thickness”
Advantages of Composite
Materials over Metals for
Aerospace
• Light weight
• Resistance to corrosion
• High resistance to fatigue damage
• Reduced machining
• Tapered sections and compound contours easily accomplished
• Can orientate fibers in direction of strength/stiffness needed
• Possible reduced number of assemblies and reduced fastener count
when co-cure or co- consolidation is used
• Absorb radar microwaves (stealth capability)
• Thermal expansion close to zero reduces thermal problems in outer
space applications

Disadvantages of Composite
Materials over Metals for
Aerospace
• Corrosion problems can result from improper coupling
with metals, especially when carbon or graphite is used
(sealing is essential)
• Degradation of structural properties under temperature
extremes and wet conditions
• Poor energy absorption and impact damage
• May require lightning strike protection
• Expensive and complicated inspection methods
• Reliable detection of substandard bonds is difficult

Design Comparison Studies for
Lockheed L-1011 Aircraft
Inboard Aileron Vertical Fin Box

Aluminum Composite
Aluminum Composite
Weight (lbs) 141 104 Weight (lbs) 858 623
# of Ribs 18 10 # of Assemblies 21 15
# of Parts 398 205 # of Parts 714 229
# of Fasteners 40800 10150

# of Fasteners 5253 2574
From “Composite Airframe Structures”, Niu

Composite Usage in Boeing 777

767 exterior composite parts
07/09/23 AME
Chart courtesy of Composites NIGERIAN
Market COLLEGE OF AVIATION TECHNOLOGY, ZARIA
Reports 25
Sandwich construction

Honeycomb sandwich
construction

Applications of composites

Building Composite Parts
Composite parts are built by

laying up multiple plies
(layers) using molds (or
tools) then cured under heat
and pressure.

Combining the Fibers with Matrix
There are several methods for arranging the fibers

and plastic in the desired shape. We can arrange the
fibers, usually as a fabric, in the mold and then pour
on the liquid matrix material. For one part we might
hand cut the fabric and fit it into the mold .

Ply Cutting and Kitting
For a production system we

wish to make the same part
many times, in the most
efficient manner, and have the
same process every time.
In this case we use a CNC
cutting machine to cut the
patterns out, then assemble a
“kit” of raw materials to make a
part.
07/09/23 Photo courtesyAME NIGERIAN

Accudyne COLLEGE
Systems, Inc OF AVIATION TECHNOLOGY, ZARIA 33
Wet Lay Up
We can arrange the fibers, usually as a fabric, in the mold and

then pour on the resin. Typically the resin is a two part
formulation that, once mixed reacts in a fixed time.
In order to make the lightest part with the necessary strength, we
must control the amount of resin we use on the part.
The process includes;
•Laying the fabric in the mold
•Saturating the fabric with mixed liquid resin
•Working the resin into the fabric so that it conforms to the mold
•Adding another ply of fabric
•Repeat the application of resin and working as above
•Continue until all the plys are in place, excess resin has been
worked to the edges, and the composite conforms to the mold
Wet Lay Up, contd.

PrePreg Lay Up
In wet layup it is very hard to control the amount of

resin.This problem may be addressed by
impregnating fabric with a pre-mixed resin. This
“prepreg” material is held at low temperatures to
retard the curing process.
The prepreg sheets or tape are laid into the mold, and
heated to cure.

Debulking the Part

Oven Cure
Once the layup is accomplished and

the part is debulked, we can put it into
a furnace to cure the resin. Typically
the parts are instrumented with a
thermocouple to track the temperature
of the part in the oven. The
temperature of the oven is increased
until the thermocouple registers the
correct curing temperature and then
the part is “soaked” at temperature
until it is cured.

Autoclave Cure
Photo courtesy WSF Ind & ASC Process Sys.

Typical Autoclave Cycle

Vacuum Resin Infusion
Vacuum resin infusion is similar to wet

lay up except that the fabric is laid out
in the mold, the part is vacuum
bagged, and resin is pulled into the
bag and through the fabric by a
vacuum pump.
Photos courtesy Airtech Adv. Materials

Automated Lay Up

Tow Placement
07/09/23 Photo courtesy Accudyne AME NIGERIAN

Systems, COLLEGE Machine
Inc & Cincinnati OF AVIATION TECHNOLOGY, ZARIA 43
High Dexterity Tape Placement

Accudyne COLLEGE
Variable Angle Ply Lamination

Accudyne COLLEGE
Large Parts
07/09/23 courtesy ATK AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 46

Future Directions
• More Automation
• Embedded sensors and actuators
• “Out of Autoclave” high performance
materials

Subsequent Composites
Modules
 Composite Specifications in Drawings

 Manufacturing Techniques
 Process Control and Tooling
You Have Just Completed

The Introduction To Composites
Aircraft wood
• Although most aircraft are now made from metal and

composite materials, wood is still an important
constructional material for certain types of light aircraft

Types of wood
• There are two principal types of wood

• Softwoods
• Hardwoods

Structure of wood

Properties of wood
• has a high strength/weight ratio

• has a high modulus of elasticity which is greatest in
the direction of the grain
• can withstand bending and compression loads

Evaluating wood
• Moisture content: For general guidance, the correct

moisture content should be 15% with a tolerance of 2%.
• Grain inclination

summary

Mastery test
• 1 HOUR

Materials Module 3

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AIRCRAFT ENGINEERING

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA PPT1.1

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA PPT 1. 2

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA PPT 1. 3

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA PPT 1. 4

• Thermoplastics - reversible in phase by heating and

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA PPT 1. 5

• They are resistant to corrosion

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA PPT 1. 6

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 7

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 8

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 9

copyright J. Anderson, 2008

copyright J. Anderson, 2008

Note that for the same level of

unidirectional (all in the same

Varying fiber direction

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 13

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 14

copyright J. Anderson, 2008

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 16

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 17

Plastics are polymer materials, that is to say that they

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 19

Aluminum is an “isotropic material”, which means it

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 21

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 22

Inboard Aileron Vertical Fin Box

Weight (lbs) 141 104 Weight (lbs) 858 623

# of Parts 398 205 # of Parts 714 229

# of Fasteners 40800 10150

From “Composite Airframe Structures”, Niu

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 24

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 27

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 28

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 30

Composite parts are built by

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 31

There are several methods for arranging the fibers

copyright J. Anderson, 2008

For a production system we

07/09/23 Photo courtesyAME NIGERIAN

We can arrange the fibers, usually as a fabric, in the mold and

copyright J. Anderson, 2008

In wet layup it is very hard to control the amount of

copyright J. Anderson, 2008

copyright J. Anderson, 2008

Once the layup is accomplished and

copyright J. Anderson, 2008

Photo courtesy WSF Ind & ASC Process Sys.

copyright J. Anderson, 2008

Vacuum resin infusion is similar to wet

Photos courtesy Airtech Adv. Materials

copyright J. Anderson, 2008

07/09/23 Photo courtesy Accudyne AME NIGERIAN

07/09/23 Photo courtesyAME NIGERIAN

07/09/23 Photo courtesyAME NIGERIAN

07/09/23 courtesy ATK AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 46

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 47

 Composite Specifications in Drawings

You Have Just Completed

• Although most aircraft are now made from metal and

07/09/23 AME NIGERIAN COLLEGE OF AVIATION TECHNOLOGY, ZARIA 49