INTRO TO COMPOSITE

HISTORY
One of the earliest composites is adobe brick
which its straw mixed with mud or clay to build
house
Another example of early composite was plywood
where different types of wood compress together
and bonded by resins
In the early stage of composites, investigation was
done due to lack of construction materials for use
of aviation where high strength low weight
capabilities is a concern.
Hence in World War II the aircraft construction
evaluate and improved from metals construction
until the introduction of composites material.
 HISTORY OF COMPOSITE

Early aircraft structure

are made from wood,
fabric and metal.
Composite airplanes
were actually
introduced during the
1970's when Ken
Rand introduced the
KR-1
COMPOSITES FUNDAMENTALS

Composites is a bonded structure using

chemical (resin) method.
Composites is a combination of 2 or more
element that;
- Differ in composition?
- Difference in identities and properties?
 COMPOSITES ELEMENT

Generally 2 or more elements includes;

Reinforcing Fibers
Matrix System
Core Materials
FUNCTIONS OF ELEMENTS

COMPOSITES
FIBERS MATRIXS CORE
Providing Bonding element Act as central
structural strength members
Hold the reinforcement in
desired position Giving more
compressive strength
Giving strength
to the structure
Transfering/Distributing
stresses

Type? Type? Type?

 A/C COMPOSITES STRUCTURES

In general A/C composites structures are;

COMPOSITES

LAMINATE SANDWICH
STRUCTURES STRUCTURES
As such repair on A/C composites will only be done
on this 2 structures.
 WHY COMPOSITES?

Generally composites technology is chosen due to reasons listed below;

High strength to weight ratio (High strength + less weight)

Strength and stiffness can be customized (Alteration to counter impact or
stresses)
High resistance to fatigue & outstanding durability (long service hours)
Does not corrode like metal. (Highly corrosion resistance)
Complex shape built by using less mould (Example: Fuselage for small
A/C uses 1 mold)
Ease of maintenance compare to metal (Obvious defects will easily see
by inspection + repair)
High operating temperature (Fiberglass & Carbon can withstand heat up
to 500C to 1000C)
Exceptional formability (complex design of a typical composites can be
fabricated)
Reduced parts counts (Example: 1 mold for fuselage & 1 mold for wing
section)
 COMPOSITE vs METALLIC

Metallic Composite
High thermal Low thermal
expansion expansion
(absorb heat fast)
Corrode Does not corrode
Complex construction Simples
construction
Low strength to weight High strength to
ratio weight ratio
 SUMMARY: ADVANTAGES

The advantages of composites may be summarized as:

Stronger and stiffer than metals on a density basis

Lighter than steel by 80% and aluminum by 60%
Superior stiffness-to-weight ratios
Typically, reinforcing materials are strong with low densities while
the matrix is usually a ductile, or tough, material. If the composite is
designed and fabricated correctly, it combines the strength of the
reinforcement with the toughness of the matrix to achieve a
combination of desirable properties not available in any single
conventional material.

Capable of high continuous operating temperature.

Highly corrosion resistant in the most corrosive environments

Reinforcement can be altered to counter drastic service environment

(i.e fiber placement) to minimize thermal stresses
 SUMMARY: ADVANTAGES (cont.)

Exceptional formability
Composites can be formed into many complex shapes during
fabrication.

Outstanding durability
Well-designed composites have exhibited excellent
characteristics, even in extremely harsh environments

Low investment in fabrication equipment - Long term

investment

Reduced Part Counts

Parts that were formerly assembled out of several smaller by
metallic components can be fabricated into a larger single
part by composites. This reduces manufacturing and
assembly labor and time.
 SUMMARY: ADVANTAGES (cont.)

Corrosion Resistance
The non-reactive nature of many resins and reinforcements can be custom
selected to resist degradation by many common materials and in corrosive
environments.
Benefits include lower maintenance and replacement costs due to
corrosion problems.
Composites stand up well to heat and corrosion. Making them ideal for
use in products that are exposed to extreme environments such as boats,
chemical-handling equipment and spacecraft. In general, composite
materials are very durable

Low Observable (War strategy)

Composites is invisible - Radar works by sending out directional radio waves
(electromagnetic radiation) through the air, then listening for a reflected
return from an airplane or other object made from metal. Composites
however are normally transparent to electromagnetic radiation i.e no
reflected waves. As such cannot be detected.
 SUMMARY: ADVANTAGES (cont.)

Safety
- Composites are less likely than metals (such
as aluminium) to break up completely under
stress. A small crack in a piece of metal can
spread very rapidly with very serious
consequences (especially in the case of
aircraft).
- The fibres in a composite however act to
block the widening of any small crack (stop
crack) and to distribute the stress around.
 DISADVANTAGES

The downside of composites is usually the overall

manufacturing cost.
(Mold + Labor + Material + Storage + Inspection +
Packaging etc.)
Common composites delamination problems is due
to environment moisture. Small opening / crack on
composites surface will allows moisture entrapment.
Composites tend to break without warning
(catastropic failure = sudden failure) if engineers fail
to identify defects and proper repair method.
 TYPES OF COMPOSITES

Particle-reinforced composites (Random)

Fiber-reinforced composites (Laminate)

Structural composites (sandwich structures)

COMPOSITES APPLICATION
Boeing 767
- Honeycomb sandwich construction.
- Face sheets are made of carbon fiber and
carbon/fiberglass hybrid
Fokker 50
- Wing fixed leading edge, fuselage doors,
radome, on the vertical/horizontal stabilizer,
and rudder.(Aramid)
- Floorboards (Carbon)
- Engine cowling (nozzle)
APPLICATION (CONT.)

B2 Bomber
- The longerons, weapon bay doors, aft
equipment bay doors and flaps
- Aramid fiber is used for protection against
FODs
Grumman X-29
- The wings on the Grumman X-29
experimental plane made use of a feature of
composites that allow them to bend in one
direction but not another.
The Lockheed F-22
uses composites for
at least a third of its
structure.
The wings on the
Grumman X-29
experimental plane
made use of a feature
of composites that
allow them to bend in
one direction.
Composites Drawing and Manuals
PURPOSES OF A/C DRAWING

Maintaining the aircraft quality in terms of similar

model to different types of customer.
Manufacturers have standardized the a/c
manufacturing process for the purpose of safe and
airworthy.
Aircraft quality must conform to various procedures
which are represented in the Technical Drawing and
Technical Documents.
Examples of technical drawings are such as
Assembly Drawing, Installation Drawing, Illustrated
Parts Catalog etc.
Example of technical documents are such as
Structural Repair Manual, Parts List, Technical Log
etc.
 IMPORTANCE OF STANDARDIZING
TECHNICAL DRAWING FORMAT

MAINTAINING A/C STANDARDIZE DRAWING LANGUAGE

QUALITY DURING PROCESS TO JUSTIFY THAT CAN BE
PRODUCTION SAFE AND UNDERSTOOD
AIRWORTHY GLOBALLY
Drawing engineering is
the drawing produced by
designer of engineering
as the equipment to
communicate between
engineers with other
organization.
 Customer req.

Drawing - Grafic language to

Designer Assembly
communicate and discuss ideas
between Eng.

Quality Eng. Production Eng.

 However the information in the drawing
must be :
Clearly
Short
Completely
Not double meaning and
Up to date
Generally A/C drawing can be;
Manual
Computer Aided Design
TYPES OF DRAWING AND TERMINOLOGY

Assembly Drawing
Show a number of detail parts
or subassemblies that are
joined together to perform a
specific function.
It shows how the parts are
related to form the complete
assembly of a component.
Joined together are usually
recognized as a unit.
TYPES OF DRAWING AND TERMINOLOGY

Design Sketches
Outline of initial design
ideas, requirements,
calculation and concepts.
Used to convey the
design parameters to the
layout designer.
No specific dimensions
are determined and the
components are drawn or
drafted not into scale.
TYPES OF DRAWING AND TERMINOLOGY

Detail Drawing
Shows all information
necessary to determine the
final form or to purchase a
part.
Give manufacturing data
needed to fabricate each
part.
Must shows all complete and
exact description of the part
including shapes,
dimensions, tolerances,
surface finish and the heat
treatment specified.
TYPES OF DRAWING AND TERMINOLOGY

Installation Drawing
Gives complete
information for
placing details or
subassemblies in
their final position in
the airplane.
The drawing can
also show the
assembly and the
detailed part
assembly of the
component.
TYPES OF DRAWING AND TERMINOLOGY

Illustrated Parts Catalog

Drawing that is used indicate
component used and
location it is assemble or
installed.
Accompany by no.of unit,
part no. and item name.
Usually having own document
sets.
TYPES OF DRAWING AND TERMINOLOGY

Layout Drawing

Made to develop the initial

design of a unit or machine.
Show all the information
necessary to make an
assembly or a detail drawing.
Not a complete drawing but
shows the look in every view
(angle) of the aircraft or its
component and the location of
the desired component will be.
TYPES OF DRAWING AND TERMINOLOGY

Tooling Drawings
Shows how to make
tools that are used to
fabricate, assemble,
or install airplane parts.
Composite tools can
be generated by this
type of drawing if it is
used as a tool or mold
during the fabrication or
machining of the
composite part.
DRAWING TERMINOLOGY
(General Overview)
 Typical Composites Drawing Layout
Ply Table Revision Block

Drawing
Area

Notes

UNIKL-MIAT

Title Block
Zones
 LAY OUT DEFINITION
Title Block
- Located @ lower right corner on any type of drawing
- Info on: Drawing title + Drawing size + Drawing no. + Scale + Pages + Sheet number +
Personnel

Revision Block
- Located @ top right hand corner
- Info on: Latest version of drawing + Person responsible for revision

Zones
- Identify location of revision for changes etc. Read by Alphabetical followed by number.
A4, B4, C4
 LAY OUT DEFINITION

Notes
- Explain the deviation from the information found in title block @ procedures @ process @
specification @ drawing
- Identify by Flag note

Ply Table
- Only for composites drawing.
- List: All information on type of material + Ply number + Orientation of fibers
PART IDENTIFICATION ON COMPOSITES ASSEMBLY

Drawing part list usually refers to a list of one complete assembly.

However any changes in

notes will cancel the old
notes with one straight line.
And further identification @
notice of cancelation of
notes is by using drawing
change notices
 DRAWING: PART LIST

Drawing part list is including:

Individual part numbers,
Part name,
description of each part
The material and quantity of all items
required for one complete assembly.
Notes & Flag notes
Notes - are used for such a large
variety of purpose
Local Notes: - represented by flag
notes apply to a specific portion,
surface or dimension on a drawing
for special Application)

Flag notes
Flag Number, letter, or
Indicator symbols are drawn 1
inside the flag to
indicate across
reference.
Notes: Letters or
symbols are only for
special application
DRAWING: Commonly used composite designations & terms

Designated $
Represent Tool side
during assembly base
on composite part
surface starting from
fiber plies 1
The sequence of plies
is controlled from the
tool surface.

Surface Tool Control

DRAWING: Commonly used composite designations & terms

Core location and

edge of ply are
determined on the
drawing.
The longitudinal
direction (ribbon)
are represented by
the honeycomb
Core details:
section Ribbon Direction
 PLY NUMBERING

Fiber layer is represented by

ply no. OR designated by P

Each ply level of a composite

assembly shall be given a ply
number; P1, P2, P3 and so
on. Plies
sequence
(Each identical ply shall
receive its own number)
A number shall also be
assigned to each individual
ply piece on any one ply
level.
Ply numbers shall be in
sequence starting with P1 on
the tool side. Tool side Ply No. 1
 PLY NO. CHANGES

Ply numbers should be kept in

sequence unless excessive drafting
revisions are required.
Revised and added plies should be
numbered out of sequence (e.g. P1,
P2, P10, P4, P5) when the old and
new part numbers are shown on the
same drawing views.
DRAWING: Commonly used composite designations & terms

A dash number (-) shall be assigned as follow:

To each final composite

assembly.
To cure composite ply
groupings to be bonded
together by secondary
bonding into a final
composite assembly.
To each integrally bonded
non composite component
of a composite assembly.
Typical Secondary bond View
Bond -4 precured parts with -5 precured parts
 COMPOSITES DRAWING: PLY TABLE

Determine amount of
plies
Sequence of layers
Material type of each
ply Amount of ply

Orientation of fiber
direction
Determine drawing
control no.of each ply
Revision each ply Ply orientation Material type
NA (natural axis) for
laminate
 Ply Table Location

Shall be located on sheet 1 for

drawing with an automated part lists.
Shall be on sheet 1 or sheet 2 for
drawing with manually prepared part
lists, depending on space available.
LAY UP / FABRICATION REQUIREMENT

Usually involve with;

Identifying ply orientation
Identifying ply stack up (sequence)
Identifying tool side surface
designation
Identifying close tolerance
dimensioning (lay up size etc.)
 PLY ORIENTATION ON PART

Used to designate
fabric warp/fill/bias
direction
0 direction @ warp
shall be the primary
fiber direction for
the material used.
 PLY AND LAMINATE AXES

Note:
Warp Fibers align at 0
direction
Weft/Fill Fibers align at
90 direction
Bias Fibers align at 45
direction
KEY TO COMPOSITES STRENGTH

Composites part strength can be altered by

specific fiber placement in order to have
high strength & high modulus part
Fiber orientation with multiple load path
to counter forces should resist damage
Strength and stiffness (modulus) is
much greater if fibers is align parallel to
force than perpendicular direction to
force Fiber

Force

Force
FIBER REINFORCEMENT FORMS

Fiber Cloth

Fiber Tape
LAMINATE PLY ORIENTATION CODE

Each laminate is labeled by its ply

orientation. The plies are listed in
sequence, set off by brackets, starting
from the side indicated by the code arrow.
 LAMINATE PLY ORIENTATION CODE

Individual adjacent laminates/plies are

separated by a slash if their angles differ.
LAMINATE PLY ORIENTATION CODE

Code for Fabric Plies

Code for Tape Plies

Code for Tape +

Fabric Plies
LAMINATE PLY ORIENTATION CODE

Adjacent plies of the same angle of

orientation are shown by a numerical
subscript.
 LAMINATE PLY ORIENTATION CODE

For tape only: when is used, two

adjacent plies are indicated, with the
top symbol being the first of the two.

* Top symbol - Depends on the tool surface

LAMINATE PLY ORIENTATION CODE

When the laminate is symmetrical,a

subscript S is used to indicated that the
code for only one half of the laminate
shown.
LAMINATE PLY ORIENTATION CODE

When the laminate is symmetrical and

has as odd number of plies the center
ply is over lined to indicate that it is the
midplane.
EXAMPLE # 2
EXAMPLE # 3
EXAMPLE # 4
EXAMPLE # 5
EXAMPLE # 6

Fiber direction on different composites parts;

EXAMPLE: CODE LAYER SEQUENCE (TAPE PLIES)

90
[0 / 90]
0

-45
[0 / 45]
+45 $
0 (Toolside)

0
[ 45 / 0]
-45 Note:
A complete
+45 laminate is set by
bracket.
 EXAMPLE: CODE LAYER SEQUENCE (TAPE AND FABRIC PLIES)

Note:
(45)
[(0,90) / ( 45)] Same angle of
(0,90) orientation -
subscript.

(0, 90)
[(0,90)] 3 (0, 90)
$
(0, 90)

45
45
[(0,90) / 453] Note:
45
Diff.orientation is
(0, 90) diferentiated by
slash.
EXAMPLE: CODE LAYER SEQUENCE (TAPE PLIES)

+ 45
-45
0
[ 45/ 0/ 90]S
90
90 Note:
Symmetrical
0 layers.
-45
+45

$
EXAMPLE: CODE LAYER SEQUENCE (FABRIC PLIES)

(0, 90)
[(45) / (0,90)]2
(45)

(0, 90)

(45)

$
EXAMPLE: CODE LAYER SEQUENCE (FABRIC PLIES)

(0,90)
(0,90)
(45)
[(0,90)2 / (45)]
(0,90)
Note:
(0,90)
Symmetrical laminate with odd
numbers of plies will have
center plies overline known as
$ midplane.
EXAMPLE: CODE LAYER SEQUENCE (FABRIC AND TAPE PLIES)

( 45)
90
[( 45) / 902 / 0]
90
0
90
90
( 45)

$
ANGULAR AND LINEAR DIMENSION
(CLOSE TOLERANCE ON DRAWING)
TYPICAL SYMBOLS ON COMPOSITE DRAWING

Honeycomb Section

No 12, 13, 14 Represent the fiber

layers
No 9 Represent the filler
No 11 Represent the h/comb core
HONEYCOMB TYPICAL SYMBOL

HONEY COMB CORE

FOAM CORE

MILLED FIBER FILLER CORE

RESIN INJECTION
 TECHNICAL DOCUMENT
User + Supplier + Producer + Manufacturer need
to follow a standard technical documents in order
to have a good and quality parts. All parts have
to go thru stringent procedures and inspection
before assembly.
All documents are therefore must comply with the
requirement set by Aviation Regulatory body;
example the FAA; the JAA; the DCA and others
The main purpose of a technical documents is to
have the tracebility history of an aircraft parts
e.g.

Raw Material Part retired / destroyed / obselete

 TECHNICAL DOCUMENTS

Discussion on important documents

found in the composites industry;
Composites Technical Documents

Composites Structure Manual Composites Maintenance Manual

Material docs (For qualification Structural Repair Manual (SRM)
& quality of material) Service Bulletin
Processes docs Other composites repair docs
Inspection docs
All available docs during the
manufacturing process or repair
EXAMPLE: MATERIAL BULLETIN
COMPOSITES: STRUCTURAL REPAIR MANUAL (SRM)

Content of SRM:
Material used
Material identification
Technical data
Procedure/Method of repair
Allowable damage (Size)
Repair sketch design
 EXAMPLE: SEARCHING FOR REFERENCES; SRM

Manual arrangement&
Number System for SRM
ATA 100 - Air Transport Association
Specification 100

Finding reference
Chapter Section - Subject
ADDITIONAL REFERENCES COMPOSITES REPAIR

Component for Repair

For this purpose document such as below is required:

Source of repair materials and equipment- 51-30-00

Drilling and machining of composite structure-51-20-07
Aerodynamic smoothness requirements-51-10-01
Resin mixes, adhesives and prepreg materials info.
Others.
 EXAMPLE

Procedure of repair
in SRM
EXAMPLE: SRM BOIENG

Structural Repair
Manual: BOIENG
737
 EXAMPLE: SRM BOIENG

Allowable damage
Repair sketch design
 EXAMPLE: SRM BOIENG

Allowable damage
Repair sketch design
SERVICE BULLETIN (SB)
The SB is produced by
manufacture if there is a
complain from operator or there is
a lack of design.
The SB are issued to notify others
of design defects, possible
modifications or a change in
approved maintenance
practices.
 SERVICE BULLETIN (SB)
The general information in service bulletin is:
Planning Information such as reason,
affectivity, description and compliance, man
power, publication affected and reference.
Material Information such as parts required
per aircraft, special tools and equipment
required; and part required modifying spares.
Accomplishment Instruction such as job set
up, removal, preparation and installation, test
and close up.
EXAMPLE: SERVICE BULLETIN
Other technical documents
Common documents that accompany a drawing

Part List Engineering Engineering Advance

- Providing info on Changes Change Request Drawing
item number; part
number; drawing
- Record changes to - Document used to initiate a Change Notice
product during change in part or assembly
number; part -To notify changes to an
manufacturing
name; material ID existing drawing
- Official record of
changes to be made on
an existing drawing
-Issues to describe
cnahges w/hout changing
the original drawing
- Quick and economical
procedures than re-
drafting the drawing