TM0500291

Transnational Composites Training

Mike Stephens
ESACT

AIRBUS S.A.S. 2006. All rights reserved. Confidential and proprietary document.

Composite Familiarization
For Training purposes only

Table of contents
1- Introduction 2- Fibre Material 3- Fibre Form 4- Matrix Material 5- Composite Form 6- Manufacturing Process 7- Assembly

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Composite Stress - Familiarization - For Training purposes only-

Page 2

1- Introduction
General Definition :A complex material, such as wood or fiberglass, in which two or more distinct, structurally complementary substances, especially metals, ceramics, glasses, and polymers, combine to produce structural or
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functional properties not present in any individual component.

Today, when we speak of composite materials, or just "composites", we are referring to the highly engineered combinations of polymer resins and reinforcing materials such as glass/carbon fibers.

Composite Stress - Familiarization - For Training purposes only-

Page 3

1- Introduction

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Composite Stress - Familiarization - For Training purposes only-

Page 4

1- Introduction
Composites on A380
GLARE in Upper Fuselage CFRP Ailerons CFRP Vertical Tail Plane CFRP Spoilers CFRP Floor Beams for Upper Deck
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CFRP Rear Pressure Bulkhead

CFRP Outer Flaps

CFRP Section 19.1

CFRP Horizontal Tail Plane CFRP J-Nose Radome

CFRP Wing Ribs

CFRP Section 19

LBW, Lower Fuselage

CFRP center wing box

Landing Gear Doors

Page 5

Composite Stress - Familiarization - For Training purposes only-

1- Introduction
CFRP on A400M
Centre Wing Box Fairings
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HTP and elevator

VTP and rudder

Fairings Movables Wing box Sponsons Cowlings LG doors

Composite Stress - Familiarization - For Training purposes onlyPage 6

1- Introduction
2500

Metals Vs Composites
Higher Strength Higher Stiffness No plasticity Lower strain levels Lower fracture energy
N/mm2

IM Carbon UD Tape

Fibre Characteristics
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2000 HS Carbon UD Tape

1500

Stress

1000

HS Carbon fabric

Aluminium 7075-T6

500 Glass fabric 0.0

Resin Characteristics
Lower strength
Lower Stiffness

Strain

0.005

0.01

0.015

0.02

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Page 7

1- Introduction
Composites Vs Metals
Structural Issues
Interlaminar/Through thickness failures

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S
Through Thickness

F
Interlaminar shear
+

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Page 8

1- Introduction
Composites Vs Metals
Structural Issues
Environmental effects (Heat / Moisture reduce Material Properties)

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Page 9

1- Introduction
Composites Vs Metals
Structural Issues
Environmental effects (Heat / Moisture reduce Material Properties)
-1- Hole effect in tension after wet ageing -2- Hole effect in compression after wet ageing
1.4 1.2 1
0.8

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1.2

0.8
0.6

0.6
0.4

0.4
0.2

0.2 0

Composite Stress - Familiarization - For Training purposes only-

Page 10

1- Introduction
Composites Vs Metals
Structural Issues
Impact (Barely Visible Impact Damage - BVID)

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Page 11

1- Introduction
Composites Vs Metals
Structural Issues
Notch Sensitivity different to metallics

Plastic deformation relives stress peaks

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High stress region

METALLICS

COMPOSITES
Stress peak behaviour different to metallics

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Page 12

1- Introduction
GENERIC METHODS

Composites Vs Metals
Manufacturing
Methods
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Composite
Lay -up to shape Bolt/Bond Inspect

Metal
Machine Bolt Resin Rich Area

Defects (e.g Resin rich areas, inclusions, voids, incorrect ply lay-ups etc) Tolerances > metals (Thickness Variations, springback, warpage)

Cover

Cost
Material ~ 80-100% > metals Assembly/Machining ~ 10 -15% > metals In service (maintenance etc) ~ 30% < metals

Angular variation - spring back Spar Spar flange

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Page 13

1- Introduction

When deciding what material and structure to use, it is necessary to know/consider;

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What are the options? What are the most important characteristics?

What is the Airbus initial choice and what are the important issues to take into account during decision making?

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Page 14

2- Fibre material Design Approach

Fibre Material
Carbon Glass Aramid Quartz
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Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies

Fibre Form
NCF Woven pre- form Uni directional Chopped strand

Lamina Laminate Sandwich

Composite Form Manufacturing processes Assembly

Pre-Preg RTM RFI Forming
Bonded Bolted Pre-Preg.Pre impregnated NCF Non crimped fabric RTM Resin Transfer moulding RFI.. Resin Film infusion

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Page 15

2- Fibre material Fibre Materials - Options

Carbon
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Glass

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Page 16

2- Fibre material Fibre Materials - Glass

Characteristics
Low cost
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E-Glass - Electronic glass High strength/ weight ratio

Outstanding dielectric properties Good fatigue Good environmental resistance Low compressive strength

Low Density = 2.6g/cm3, Moderate stiffness ~60% CF, Good strength ~60-80% CF,

S-Glass - High strength glass Higher compressive and tensile

strength whilst being less dense than E-Glass

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Page 17

2- Fibre material Fibre Materials - Carbon

Characteristics
Cost ~10-15 x glass
Excellent balance of performance

and price

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High/Very High Stiffness (cf Glass) High/Very High Strength (cf Glass) Very Low Density = 1.6g/cm3

Examples ~ T800, AS4, HTA

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Page 18

3- Fibre Form Design Approach

Fibre Material
Carbon Glass Aramid Boron
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Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies

Fibre Form
NCF Woven pre- form Uni directional Chopped strand

Lamina Laminate Sandwich

Composite Form Manufacturing processes Assembly

Pre-Preg RTM RFI Forming
Bonded Bolted

Pre-Preg.Pre impregnated NCF Non crimped fabric RTM Resin Transfer moulding RFI.. Resin Film infusion

Composite Stress - Familiarization - For Training purposes only-

Page 19

3- Fibre Form Fibre Form - Options

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UD (Unidirectional) Non Crimp Fabric (NCF)

Woven
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Chopped Strand (Mat)

Page 20

3- Fibre Form Fibre Form - UD

1 2
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Characteristics

2 1

High strength & stiffness (1-1) High compression stability Low drape capability Un-crimped fibres

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Page 21

3- Fibre Form Fibre Form - Woven

W ef t
Characteristics Lower strength & stiffness Lower compression stability High drape capability Complex/double curvatures Crimped Fibres

ve ea

2
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Page 22

3- Fibre Form Fibre Form - (NCF)

1 2
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Characteristics
High cost (raw material) High deposition rate High tension strength/stiffness (1-1) Lower compression stability Slightly crimped fibres Good drape? Variability?

2 1

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Page 23

3- Fibre Form Fibre Forms - AIRBUS Initial Choice

(Woven, NCF)
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Important Issues
Thickness Impact Resistance Drapeability Strength & Stiffness Manufacturing/Material costs
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(UD-0.1 to 0.25,Woven-0.2 to 0.35, NCF-.866) (UD <NCF<Woven) (UD<NCF<Woven) (Woven<NCF<UD) (NCF<Woven<UD)

Page 24

4- Matrix Material Design Approach

Fibre Material
Carbon Glass Aramid Boron
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Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies

Fibre Form
NCF Woven pre- form Uni directional Chopped strand

Lamina Laminate Sandwich

Composite Form Manufacturing processes Assembly

Pre-Preg RTM RFI Forming Pre-Preg.Pre impregnated NCF Non crimped fabric
Bonded Bolted

RTM Resin Transfer moulding RFI.. Resin Film infusion

Composite Stress - Familiarization - For Training purposes only-

Page 25

4- Matrix Material Matrix Materials - Options

Thermoset Resins

Epoxies: most widely used, best properties for primary

structures, principal resin type in current graphite production use.
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Polyester & Phenolics: used in secondary structures, cabin

interiors, primary with fibre glass

Bismalemides: good structural properties, high temperature

resistance, alternative to epoxy, expensive

Polyimide: specially use for high temperature application

Thermoplastic Resins

Thermoplastics are used for parts with low tolerance range,

they have good material health, good stability comparing to possible parameter variations and smooth aspect
Composite Stress - Familiarization - For Training purposes onlyPage 26

4- Matrix Material Thermoset resins

Polyester Phenolics Bismalemides Cyanate Esters Polyamide Low strength / weight ratio (boats/Cars) Low strength / weight ratio (interior dcor & electronics) Good FST (fire, smoke and toxicity) properties
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High temp, expensive, difficult to process (matrix microcracking) Expensive, electrically transparent, low moisture absorb Very high temp, expensive Lower properties than epoxies
Good resistance to chemical attack Adequate high temp properties Good secondary bond strength Can be formulated to meet a wide range of processing

Epoxies

Available as Room temp epoxies (eg Araldite) Elevated temperature curing (pre preg)

Composite Stress - Familiarization - For Training purposes only-

Page 27

4- Matrix Material Matrix Materials - Epoxy

Characteristics

Tg ~ Glass transition temperature, determines max operating temperature of material (from 100 to 150 degrees) depending on environment
2 Module G (N/mm )

0.50 T300 / BSL 914

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Brittle glassy state Liquid or rubbery state

0.40

T300-914 glass transition point graphic

Tg
103 2 WET 2 5.102 1 1 DRY

0.30

0.20

0.10

40

60

X X 80 100 120 140 160 180 200 220 240 260 280 300 320 340 95C 120C Temperature (C)
Page 28

Composite Stress - Familiarization - For Training purposes only-

4- Matrix Material Matrix Materials - Epoxy

Characteristics

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Tensile Strength 60-80 MPa Tensile Modulus 3000-4000 MPa Performance decrease by moisture pick-up and T Brittle Resistant to aggressive media (Skydrol, de-icing etc) Sensitive to UV => top coat required

Composite Stress - Familiarization - For Training purposes only-

Page 29

5- Composite Form Design Approach

Fibre Material
Carbon Glass Aramid Boron
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Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies

Fibre Form
NCF Woven pre- form Uni directional Chopped strand

Lamina Laminate Sandwich

Composite Form Manufacturing processes Assembly

Pre-Preg RTM RFI Forming
Bonded Bolted

Pre-Preg.Pre impregnated NCF Non crimped fabric RTM Resin Transfer moulding RFI.. Resin Film infusion

Composite Stress - Familiarization - For Training purposes only-

Page 30

5- Composite Form Composite Form - Lamina Characteristics

LAMINA = PLY OR LAYER
Fibre
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Matrix

Mechanical: High stiffness Low stiffness Thermal: Small (-ve ) Larger (+ve) Moisture: No change Swelling & shrinkage Terminology Fibre Weight Fraction Fibre Volume Fraction Porosity
Note: Nomenclature

fwf = Wf /(Wf + Wm ) fvf = Vf /(Vf + Vm) ~60% 5% Vp = 1 - (fv + fvm)

V = volume W = weight f=fraction Subscripts f = fibre m = matrix p = pores/voids

Vp < 1-2% required for a/c structural application Vf altered during manufacturing by bleeding resin (improves Mechanical properties)

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Page 31

5- Composite Form Composite Form - Lamina

Rule of Mixtures
2 1
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E1
50 40

GN/m2

Ef-Em

30

Assume compatibility of strains: f = m = 1 E1 = Ef Vf + Em Vm

20 10

E.g. GF/PE

Em
0.1 0.2 0.3 0.4 0.5 0.6 0.7

c = f vf + m vm
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Vf

Page 32

5- Composite Form Composite Form - Laminate Definitions

LAMINATE = COMBINATION OF LAMINA Axis Orientation
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Lamina has material Axes 1 2 3 Laminate has axes x y z Orientate and define 1 2 3 with respect to x y z
3 2 1

Analysis Approaches
Individual fibre and matrix response Apparent homogeneous/orthotropic response (Average individual fibre/matrix response in laminate directions)
z z y x x y

2 1 1 2

1 2

y x

Individual Response

Apparent Response (Black Metal Approach)

Page 33

Composite Stress - Familiarization - For Training purposes only-

5- Composite Form Composite Form - Laminate Properties

Individual Lamina properties obtained from Material Qualification Data Sheets
f11,22,33T,C E11,22,33T,C f12 G12 etc
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Apparent Material Properties approximated using 10% Rule

fxxT,C = P0 x f11T,C + P45 x 0.1 x f11T,C + P90 x 0.1 x f11T,C

Nomenclature
P0 ~ % 0o fibres / 100 P45 ~ % 45o fibres / 100 P90 ~ % 90o fibres / 100

Carpet Plots Classical Laminate theory

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Page 34

5- Composite Form Composite Form - Laminate Properties

Analysis Fundamentals Isotropic Material - Metals
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Failure defined by yielding Constant stress across thickness

Anisotropic Material - Composite

Failure defined by first ply failure Variable stress across thickness

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Page 35

5- Composite Form Composite Form - Laminate Lay-up/Stacking

Ply Guidelines % any one orientation ~ 10%
60 % max same orientation
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4 plies max adjacent same orientation (depending on thickness) 45 degree angle change + - 45 on surface Balanced Symmetric
Tailoring as Required
0o DIRECTION PLIES IN SKIN TO REACT BENDING / DIRECT LOAD 45o / 135o DIRECTION IN SKIN TO REACT SHEAR 90o DIRECTION TO REACT BOLT BEARING, FUEL PRESSURE AND AERODYNAMIC SUCTION.
Composite Stress - Familiarization - For Training purposes onlyPage 36

5- Composite Form Composite Form - Laminate Lay-up/Stacking

Staggered Joints
2 1 X X DE DE IN IN R R GE GE F IB RE D IR EC

Joint Guidelines

P L Y ID T H

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AG

AG

AG

GE

IN

DE

T IO

ST

ST

S T A R
1 5 ( N o m m m ')

P O

I N

Ply Drop Guidelines

16mm Ramp 11mm

ST

Skin: 1:20 Spanwise 1:10 Chordwise Spar: as skin but may go up to 1:5 Rib: 1:20 but may go up to 1:5

NA

NA

Arrow
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Diamond
Page 37

5- Composite Form Composite Form - Laminate Lay-up/Stacking

See example drawing
Layer No
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Fibre orientation Roll Orientation Line No (Parts List) Material Stagger Index

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Page 38

5- Composite Form Composite Form Sandwich

Sandwich concept provides very stiff and strong structures They have high flexural stiffness and buckling strength.

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Page 39

5- Composite Form Composite Form - Sandwich Options & Characteristics

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Page 40

5- Composite Form
Composite Form - AIRBUS most common choice Lamina: UD Epoxy pre preg Lay-up: Tailored to suit load direction
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Sandwich: Nomex Important issues:

Strength/Stiffness (Sandwich, Lamina)

Cost (Sandwich, Lamina) Moisture Ingress (Sandwich) Availability (Sandwich, Lamina) Is it approved ? (Sandwich, Lamina) Definition of axes relative to laminate plate (Lay-up) Follow Lay-up/Stacking/Terminology rules (Lay-up/Stacking)
Composite Stress - Familiarization - For Training purposes onlyPage 41

6- Manufacturing Process Design Approach

Fibre Material
Carbon Glass Aramid Boron
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Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies

Fibre Form
NCF Woven pre- form Uni directional Chopped strand

Lamina Laminate Sandwich

Composite Form Manufacturing processes Assembly

Pre-Preg RTM RFI Forming
Bonded Bolted

Pre-Preg.Pre impregnated NCF Non crimped fabric RTM Resin Transfer moulding RFI.. Resin Film infusion

Composite Stress - Familiarization - For Training purposes only-

Page 42

6- Manufacturing Process Manufacturing Process - Options

Pre-preg Technology
(e.g. HTP, VTP)

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Resin film Technology Resin Film Infusion (RFI)

(e.g. Pressure Bulkhead)

Liquid resin Technology Resin Transfer Moulding (RTM)

(e.g. CWB Stiffeners, VTP Ribs)

Manufactured Component

Liquid Resin Infusion (LRI)

(e.g Shorts TANGO Front Spar)

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Page 43

6- Manufacturing Process Manufacturing Process - Pre Preg Technology

Generic Method Cut Plies and Lay-up
By Hand (Cheap but time consuming)

Automatic cutting and tape lay (ATL)

Forming
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Pre - forming over mould tool Hot Rolled

Curing (Autoclave)

Pre-heated Flat composite sheet First set of rollers to initiate profile

Inspection, Machining, Cleaning,

Painting

Characteristics
Material cost high Fair quality and accuracy
Second set of rollers establishing blade Final roll controlling finished profile

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Page 44

6- Manufacturing Process Manufacturing Process - RFI

Generic Method
Semi-Preg and Cut Plies
Semi-preg to hold dry fibres together
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Lay-up and Forming

Hand Lay-up semi-preg plies onto forming tool Transfer pre-form to cure tool

Curing and Infusion (Autoclave)

Full infusion during curing (Heat and Pressure)

Inspection, Machining, Cleaning, Painting

Characteristics
Fair quality Low Material Cost Time efficient
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6- Manufacturing Process Manufacturing Process - RTM

Generic Method
Cut Plies (Dry fibres + binder) Lay-up and Forming
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Hand Lay-up onto forming tool (multi-surface) Hot de-bulk creating pre-form Transfer to cure tool

Injection and curing

Liquid resin injection into pre-form Integrally heated tool for curing

Inspection, Machining, Cleaning, Painting

Characteristics
High tooling cost (High Volume Process) Low Material Cost Very good Tolerance on all faces
Composite Stress - Familiarization - For Training purposes onlyPage 46

6- Manufacturing Process Manufacturing Process - LRI

Generic Method
Cut Plies (dry fibres + binder) Lay-up and Forming
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Hand Lay-up onto forming tool (single surface) Hot de-bulk creating pre-form Transfer to cure tool

Infusion and curing

Vacuum Liquid resin into pre-form Ensure flow distribution media for resin

Inspection, Machining, Cleaning, Painting

Characteristics
Lowest quality Lowest cost
Composite Stress - Familiarization - For Training purposes onlyPage 47

6- Manufacturing Process Manufacturing Process - Tooling Concept

Issues
Fundamental in achieving high accuracy parts

Component scale and complexity Manufacturing process technology Balance between cost, accuracy, thermal mass
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Options
Steel - high accuracy for small part

Aluminum - high CTE, low cost Invar - highest accuracy, cost and durability Composite - lower thermal mass, shorter life
breather blanket caul plate vacuum bag release film

edge bars Inflatable mandrels

component

Rubber mandrels

Solid mandrels

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Page 48

6- Manufacturing Process Manufacturing Process - Defects/Inspection

Manufacturing Defects
Delaminations Broken or cut fibres Inclusions (razor blades, release film etc) Incorrect ply lay-up Variations in Vf (resin rich areas, dry patches etc) Voids/porosity Handling/machining damage Inspection - Non-Destructive Test (NDT) 100% inspection for CFRP parts after manufacture Ultrasonic Radiography, X ray Acoustography (coin tap also) Shearography
Composite Stress - Familiarization - For Training purposes onlyPage 49

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6- Manufacturing Process
Manufacturing Process: AIRBUS most common choice

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Important issues:
Strength/Stiffness properties (material)
Increase Vf of material (process) ?

Cost (material/process/tooling) Accuracy/Tolerance/Quality (process/tooling) Temperature (Tg of resin) Thermal Mass (Tooling) Non Recurring Costs (Autoclave/Facilities etc)

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Page 50

7- Assembly Design Approach

Fibre Material
Carbon Glass Aramid Boron
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Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies

Fibre Form
NCF Woven pre- form Uni directional Chopped strand

Lamina Laminate Sandwich

Composite Form Manufacturing processes Assembly

Pre-Preg RTM RFI Forming
Bonded Bolted

Pre-Preg.Pre impregnated NCF Non crimped fabric RTM Resin Transfer moulding RFI.. Resin Film infusion

Composite Stress - Familiarization - For Training purposes only-

Page 51

7- Assembly Assembly - Joint Issues

Bonded vs Bolted
Stiffness (bonded > bolted)
Aerodynamic profile (bonded > bolted) Assembly (bolted > bonded) Weight (bonded > bolted) Inspection (bolted > bonded)

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Bolted Joints
Galvanic corrosion (Titanium Bolt/Glass) Thermal coefficient mismatch Failure issues around holes Sealing Failure mode sensitive to out of plane loading

Bonded Joints
Surface preparation Operating Temperature Failure issues at bond joint Lightening strike consideration Highly sensitive to out of plane loading
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G. Peel/Disbond
Page 52

7- Assembly Assembly - Bolting

Bolted Joints Guidelines
3d
4d-6d (typ)

* For Fuel Seal 5d* Primary Load Direction

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5d

2.5d

4d-6d typ

d = next nominal/first oversize (depending on repair philosophy)

Bolted Joints Loading Distributions - Double Row

0.5 0.4
Fastener Load 0.3 Applied Load
3 Fasteners 2 Fasteners

0.2 0.1 0.0

8 Fasteners 7 Fasteners 6 Fasteners

4 Fasteners 5 Fasteners

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Page 53

7- Assembly Assembly - Bonding

Bonded Joints Options
1 2
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CO CURE
Component 1 un-cured Component 2 un-cured Cured together effectively creating a single part

1
Adhesive

CO BOND
2
Component 1 cured Component 2 un-cured Bonded together during cure of cure cycle of component 2

1
Adhesive

SECONDARY BOND
2
Component 1 cured Component 2 cured Bonded together with separate bonding operation

Bonded Joints Guidelines

For Secondary bonds only
maybe lamina 37.5o

Overlap length (for bonded repair)

Composite Stress - Familiarization - For Training purposes onlyPage 54

7- Assembly Assembly - Tolerances/Heat and Safety/Jigs

Issues
Shimming required to fill gaps between interface surfaces, restore smoothness and avoid assembly stresses
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Liquid shim : between 0.4mm and 0.7mm upper limit (harmonization ongoingdepends on design) Solid Shim > 0.5mm (validated by tests :static, fatigue)

Carbon dust extraction essential during drilling procedure In-jig access to be considered for additional jig features
Shimming tooling

Bonding tooling

Thermal mismatch between metallic jig and composite components

A340-600 Horizontal Tail Plane

Composite Stress - Familiarization - For Training purposes onlyPage 55

7- Assembly Assembly: AIRBUS most common choice

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Important issues:
Strength/Stiffness (Joints)

Weight (Joints) Cost (Joints/Jig/Shimming) Repair/Inspection (Joints) Tolerance (Jig/Shimming) Thermal Mass (Jig) Health and Safety (Joints/Jig) Access (Jig)
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7- Assembly Summary: AIRBUS most common choice

Fibre: Carbon HS or IM Resin: Epoxy, phenolics Form: UD Pre-preg
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Manufacturing Process: Pre-preg ATL Joints: Bolted (Bonded if co-cured) Shim: aim for no shim, liquid then solid/liquid if needed Important issues:
Strength/Stiffness

Weight Cost Certification

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Approval & Authoring Team

AUTHORS
Function NatCos
A-F
AIRBUS S.A.S. 2006. All rights reserved. Confidential and proprietary document.

Name
Mike Stephens

APPROVAL
Domain
Head of ESAC

Name
Chantal Fualdes

Signature
Signed electronically 27/06/2006

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Record of Revisions
RECORD OF REVISIONS
Issue
1 2 3 4
AIRBUS S.A.S. 2006. All rights reserved. Confidential and proprietary document.

Date

Summary and reasons for changes

Creation General update General update General update

For general queries or information contact: Airbus Documentation Office Airbus SAS 31707 Blagnac CEDEX France Tel: +33 [0] 561 93 49 93 Fax: +33 [0] 561 93 27 44
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AIRBUS S.A.S. 2006. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS S.A.S.. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied.
AIRBUS S.A.S. 2006. All rights reserved. Confidential and proprietary document.

The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.

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