Introduction to Composites

An Aerospace Manufacturing Perspective

Course Overview

Composite Material Structure Composite Material Components Aluminum versus Composites Advantages and Disadvantages in Aerospace Composite Applications Composite Manufacturing Techniques Subsequent Composite Modules
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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.

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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
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Fiber Reinforced Plastic Composites, contd.

Fibers

Plastic Matrix
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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

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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

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Relative Strength of Fiber and Matrix

Note that for the same level of stress, the fiber deforms much less than the resin. This leads to the composite material being much stronger in the direction of the fiber. If the fibers are unidirectional (all in the same direction) the composite material is strong in the direction of the fibers, but weak in the directions perpendicular to the fibers. We can alleviate this by adding multiple plies laid with the fiber direction different.

Carbon Fiber

Stress

Polyester Resin

Strain

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Varying Fiber Direction in Plies

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

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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

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Material Configurations

courtesy Ten Cate Avdanced Composites

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Composite Fiber Materials

Common Fibers Used in Composites Glass, or fiberglass Starts as a silica sand Carbon Starts as a polyacrylonitrile fiber

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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 cant be re-melted once cured.
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Common Thermoset Plastics used in High Performance Composites

Thermosets

Epoxy Polyester Phenolics Cyanate Esters Bismaleimide (BMI) Polyimide Nylon Polyetheretherketone (PEEK)

Thermoplastics

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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 plys 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
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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

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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

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Design Comparison Studies for Lockheed L-1011 Aircraft

Inboard Aileron
Aluminum Composite

Vertical Fin Box

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 # of Fasteners 5253 2574

40800

10150

From Composite Airframe Structures, Niu

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Composite Usage in Boeing 777

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Composite Component Content

Chart courtesy of Composites Market Reports

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Building Composite Parts

Composite parts are built by laying up multiple plies (layers) using molds (or tools) then cured under heat and pressure.

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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 .

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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.
Photo courtesy Accudyne Systems, Inc

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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
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Wet Lay Up, contd.

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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.

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Debulking the Part

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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.

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Autoclave Cure

Photo courtesy WSF Ind & ASC Process Sys.

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Typical Autoclave Cycle

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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

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Automated Lay Up

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Tow Placement

Photo courtesy Accudyne Systems, Inc & Cincinnati Machine

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High Dexterity Tape Placement

Photo courtesy Accudyne Systems, Inc

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Variable Angle Ply Lamination

Photo courtesy Accudyne Systems, Inc

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Large Parts

courtesy ATK

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Future Directions
More Automation

Embedded sensors and actuators Out of Autoclave high performance materials

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Subsequent Composites Modules

Composite Specifications in Drawings Manufacturing Techniques Process Control and Tooling

You Have Just Completed The Introduction To Composites

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