COMPOSITE

Composite for Aircraft :

• Laminates consist of multiple layers of fibre and resin (called plies) which are
bonded together into a solid material.The fibres are oriented along the in-plane
directions of principal loading to provide high stiffness, strength and fatigue
resistance and the polymer matrix binds the fibres into the material.Laminates
made of carbon fibre–epoxy resin composite are used in the most heavily-
loaded aircraft structures
• Sandwich composites consist of thin face skins (usually carbon–epoxy laminate)
bonded (often with adhesive film) to a thick, lightweight core material. Sandwich
structures are often used in lightly loaded structures that require high resistance
to bending and buckling.
Type of Manufacturing Process
• Prepreg-based processes
Autoclave curing - automated tape lay-up - automated fibre placement
• Resin Infusion processes
resin transfer moulding - resin film infusion - vacuum-bag resin infusion
- filament winding.
Carbon Fibre
• Stiff
• Aircraft structure and jet engine part
• Better fatigue properties and corrotion than metal/ high strength
alloy
• Good heat resistance (for nozzle rocket, thermal insulation, brake)
Glass Fibre
• used sparingly in aircraft structures owing to their low stiffness.
• used in structures where specific stiffness is not a design factor
(secondary structure : fairing, cabin shell).
• Glass fibre composites have low dielectric properties (radomes and
aerial covers)
Aramid (Kevlar)
• Good impact resistance against high-speed projectiles
• good dielectric properties, making them suitable for radomes
Comparison in Composite Material
Production of Prepreg and Fabrics
• Prepregs
Prepreg is a two-part sheet material consisting of
fibres (e.g. carbon)
and partially cured resin (e.g. epoxy).

The benefits of using prepreg include accurate

control of the fibre volume content and the
ability to achieve high fibre content, thus
allowing high-quality composite components to
be produced with high mechanical properties.
Production of Prepreg and Fabrics (Cont)
• Dryfabrics
The aerospace industry is increasingly using dry
carbon fabric instead of carbon-fibre prepreg to
manufacture aircraft structures. There are
several advantages gained by using fabric
rather than prepreg, including
1. lower material cost,
2. infinite storage life,
3. no need for storage in a freezer, and
4. better formability into complex shapes.
Many aircraft structural components are required to carry only light
or moderate loads. When a small load is applied on a composite
laminate, the structure is designed with a thin skin and few ribs,
frames and spars to reduce weight. When the skin becomes too thin
and the stiffeners too few then the structure loses its resistance
against buckling and, therefore, some additional form of stiffening is
required. A common solution is to build the laminate skins as a
sandwich by inserting a lightweight filler or core layer.