MODULE 6: PROPERTIES OF COMPOSITES AND ADVANCED AIRCRAFT MATERIALS

A material composed of solid materials of carry-load that are contained in a

material much weaker
Composite Material Combination of two or more materials that differ in composition
Elements do not dissolve or otherwise merge into each other
Two Types: Fiber and Matrix
Often referred to as the stronger material and the weaker material is usually
referred to as the matrix
Provides the requisite strength and stiffness that helps to sustain the
Reinforcement structural load
Its principal role of the reinforcement is to provide strength, stiffness and other
mechanical properties to the composite

Helps to maintain the position and orientation of the reinforcement and is

somewhat more brittle
Matrix It is the continuous phase of the composite
(Binder) Its principal role is to give the shape to the structure
It can be easily shaped and then hold that shape are especially useful
TYPES OF FIBER
Used for secondary structure on aircraft, such as fairings, radomes,
helicopter rotor blades and wing tips
Made from small strands of molten silica glass that are spun together and
woven into cloth
Fiberglass Two Types of Fiberglass: Electrical Glass (E-Glass) and S-Glass
Electrical Glass/E-glass: for electrical applications. It has high resistance to
current flow and is made from borosilicate glass.
S-Glass and S2-Glass: identify structural fiberglass that have a higher
strength than E-glass; produced from magnesia-alumina-silicate.
Lower cost than other composite materials
Advantages Chemical or galvanic corrosion resistance
Electrical properties (fiberglass does not conduct electricity)
Disadvantage Weighs more and has less strength than most other composite fibers
 Commercially known as Kevlar; DuPont’s name for aramid fibers
Light weight, strong, and tough
Characterized by its yellow color
Aramid Fibers Two Types of Kevlar®:
Kevlar® 49: has a high stiffness; are predominantly used in aircraft
composite reinforced plastics
Kevlar® 29 has a low stiffness
High resistance to impact damage
Advantages often used in areas prone to impact damage
Strength to weight ratio
General weakness in compression and hygroscopy
Disadvantages It stretches too much
Black fiber that is very stiff and strong, used for its rigid strength
Carbon fibers are typically carbonized at approximately 2400 F and
composed of 93% to 95% carbon
Graphite fibers are produced at approximately 3450 to 5450 F and are more
Carbon/Graphite Fibers than 99% carbon
American term: “Graphite Fiber”
European term: “Carbon Fiber”
Used for structural aircraft applications, such as floor beams, stabilizers,
flight controls, and primary fuselage and wing structure
Advantage High strength and corrosion resistance
Very costly
Disadvantages Lower conductivity than aluminum
Have a high potential for causing galvanic corrosion
Very stiff and have a high tensile and compressive strength
Have a relatively large diameter and do not flex well
Used to repair cracked aluminum aircraft skins
Boron Fibers Thin filament of tungsten (not commonly used in Civil Aviation)
instead of boron, they used utilized hybrid composite materials of ARAMID
and CARBON/GRAPHITE
Used for high-temperature applications, such as turbine blades in a gas
Ceramic Fibers turbine engine
Combined to metal matrix for high temperature applications
B. TYPES OF MATRIX
The function of the matrix in a composite is to hold the reinforcing fibers in a
Matrix System desired position.
Uses wide range of RESIN SYSTEMS to reinforced composites.
Metal Matrix Composites Composed of a metallic matrix (aluminum, magnesium, iron, cobalt, copper)
(MMC) + dispersed ceramic (oxides, carbides) or metallic (lead, tungsten,
molybdenum) phase
Ceramic Matrix Composites Composed of a ceramic matrix and embedded fibers of other ceramic
(CMC) material (dispersed phase)
Composed of a matrix from thermoset (Unsaturated Polyester (UP), Epoxy
Polymer Matrix Composites (EP) or thermoplastic (Polycarbonate (PC),Polyvinylchloride, Nylon,
(PMC) Polysterene)
+ embedded glass, carbon, steel or Kevlar fibers (dispersed phase)
Generic term used to designate the polymer
An organic polymer used as a matrix to contain the reinforcing fibers in a
Resins composite material
Two types: Thermosetting and Thermoplastics
Thermosetting Resins The most diverse and widely used of all man-made materials
Easily poured or formed into any shape
 Cure readily (by heat or catalyst) into an insoluble solid
Use heat to form and irreversibly set the shape of the part
KINDS OF THERMOSETTING RESINS
Relatively inexpensive, fast processing resins used generally for low cost
applications
I. Polyester Resins Low smoke producing polyester resins are used for interior parts of the
aircraft
Mainly used with fiberglass composites to create nonstructural applications
such as fairings, spinners, and aircraft trim
Same as those of conventional polyester resins in terms of appearance,
II. Vinyl Ester Resin handling properties, and curing characteristics of vinyl ester resins
III. Phenolic Resin Used for interior components because of their low smoke and flammability
characteristics
Most of the newer aircraft composite matrix-formulas utilize this type
Two-part systems consisting of a resin and a catalyst
IV. Epoxy Catalyst — acts as a curing agent by initiating the chemical reaction of the
hardening epoxy
Used widely in resins for prepreg materials and structural adhesives.
Advantages Outstanding adhesion, strength, and resistance to moisture and chemicals
Disadvantages Brittleness and the reduction of properties in the presence of moisture
May be either a thermoset resin or a thermoplastic
Excel in high-temperature environments where their thermal resistance,
V. Polyimides oxidative stability, low coefficient of thermal expansion, and solvent
resistance benefit the design
Uses are circuit boards and hot engine and airframe structures
Extremely high temperature resistant
VI. Polybenzimidazoles (PBI) Used for high temperature materials
Available as adhesive and fiber
High temperature capability and higher toughness than epoxy resins
Provide excellent performance at ambient and elevated temperatures
VII. Bismaleimides (BMI) Suitable for standard autoclave processing, injection molding, resin transfer
molding, and sheet molded compound (SMC)

Can be softened repeatedly by an increase of temperature and hardened by

a decrease in temperature
Thermoplastic Resins Primary advantage: processing speed
Chemical curing of the material does not take place during processing, can
be shaped by molding or extrusion when it is soft
KINDS OF THERMOPLASTIC RESINS
Possess properties of inherent flame resistance, superior toughness, good
Semicrystalline mechanical properties at elevated temperatures
Thermoplastics Used in secondary and primary aircraft structures
Available in forms of films, filaments, and powders
Available in injection molding compounds, compressive moldable random
Amorphous Thermoplastics sheets, unidirectional tapes, woven prepregs when combined with
reinforcing fibers
A high temperature thermoplastic
Polyether Ether Ketone Offers outstanding thermal and combustion characteristics and resistance to
(PEEK) a wide range of solvents and proprietary fluids
Can also be reinforced with glass and carbon
CURING STAGES OF RESINS
The components of the resin (base material and hardener) have been mixed
but the chemical reaction has not started.
 A stage The resin is in the A stage during a wet layup procedure
The components of the resin have been mixed, chemical reaction has started
The material has thickened and is tacky
B stage To prevent further curing the resin is placed in a freezer at 0 °F
Curing starts when the material is removed from freezer and warmed again
C stage The resin is fully cured
C. ADHESIVES
Glue parts together
Adhesives Pre-blends the resin and catalyst on a thin film of plastic
It is refrigerated to slow the cure rate
Rubber-toughened epoxy film adhesives are widely used in aircraft industry
Film Adhesives Supported by fibers that serve to improve handling of the films prior
to cure, control adhesive flow during bonding, and assist in bond line
thickness control
Used as an alternative to film adhesive
Used to secondary bond repair patches to damaged parts and also used in
places where film adhesive is difficult to apply.
Paste Adhesives Advantage: Can be stored at room temperature, have a long shelf life
Disadvantage: bond line thickness is hard to control
A scrim cloth can be used to maintain adhesive in the bondline when
bonding patches with paste adhesive.
About 0.025-inch to 0.10-inch thick sheets of B staged epoxy
Expand during the cure cycle
Foaming Adhesives Used to splice pieces of honeycomb together in a sandwich construction
Used to bond repair plugs to the existing core during a prepreg repair
D. CORE MATERIALS
Honeycomb The most common core material used for aircraft honeycomb structures is
aramid paper (Nomex® or Korex®)
Kraft Paper Relatively low strength, good insulating properties, is available in large
quantities, and has a low cost
Thermoplastics Good insulating properties, good energy absorption and/or redirection,
smooth cell walls, moisture and chemical resistance
Best strength-to-weight ratio and energy absorption, has good heat transfer
Aluminum properties, electromagnetic shielding properties, has smooth, thin cell walls
Good heat transfer properties, electromagnetic shielding properties, and
Steel heat resistant
Specialty metals (Titanium) Relatively high strength-to-weight ratio, good heat transfer properties,
chemical resistance, and heat resistant to very high temperatures
Aramid Paper Flame resistant, fire retardant, good insulating properties, low dielectric
properties, and good formability
Fiberglass Tailorable shear properties by layup, low dielectric properties, good
insulating properties, and good formability
Good dimensional stability and retention, high-temperature property
Carbon retention, high stiffness, very low coefficient of thermal expansion, tailorable
thermal conductivity, relatively high shear modulus
Ceramics Heat resistant to very high temperatures, good insulating properties, is
available in very small cell sizes
Used on homebuilt and lighter aircraft to give strength and shape to wing
Foam tips, flight controls, fuselage sections, wings, and wing ribs
Are typically heavier than honeycomb and not as strong
Types of Foam Cores o Polystyrene (Styrofoam)
o Phenolic
o Polyeurethane
 o Polypropylene
o Polyvinyl chloride (PVC) (Divinycell, Klegecell, and Airex)
o Polymethacrylimide (Rohacell)
Balsa Wood Available in a variety of grades that correlate to the structural, cosmetic, and
physical characteristics.
Has a considerably higher density than other types of structural cores
E. PROPERTIES OF COMPOSITES
High Strength to Weight Ratio
Lightweight
The ability for composites to withstand fire has been steadily improving over
the years
Fire resistance Fire retardant: Are self-extinguishing laminates, usually made with
chlorinated resins and additives such as Antimony trioxide
Fire resistant: More difficult and made with the likes of Phenolic Resins
Chemical & Weathering Composite products have good weathering properties and resist the attack
Resistance of a wide range of chemicals
Almost any shade of any color can be incorporated into the product during
Color manufacture by pigmenting the gelcoat used
Dark colors are not recommended as they produce excessive heat on the
surface which can lead to the surface deterioration
Translucency Polyester resins are widely used to manufacture translucent mouldings and
sheets; up to 85% of light transmission can be achieved
Design Flexibility
Low Thermal Conductivity
Manufacturing Economy
FROM POWERPOINT
Consist of two or more layers of reinforcing material bonded together and
Laminated Composites embedded in a resin matrix
Built up to desired thicknesses by using multiple layers of reinforcing fabrics
Consist of two or more layers of reinforcing material laminated together
Interply Hybrid Laminates Blending different advanced composite fabrics in a laminate can achieve the
proper balance of stiffness, strength, and weight for a particular application
The final finish of a composite structure seals the surface and creates a barrier
from moisture and ultra-violet light
Moisture is so destructive to a composite, that some manufacturers, such as
Boeing, apply a plastic coating on the composite before painting
Composite Finishes Most new-generation aircraft paint can be used on composites as well as
metallic structures, providing excellent flexibility and wear-resistance
characteristics. In addition, aircraft finishes do not deteriorate as readily as
some other types of composite finishes
Today's composite inspection techniques and nondestructive testing (NDT)
methods typically involve the use of multiple methods to accurately determine
the airworthiness of the structure
Composite Inspection Composite structures require ongoing inspection intervals along with non-
scheduled damage inspection and testing.
Proper inspection and testing methods help determine the classification of
damage, which is, whether the damage is repairable or whether the part must
be replaced
The most frequently used inspection method in aviation
Visual Inspection Pilots, ground crew, and maintenance technicians visually inspect the aircraft
on a daily basis
Tap Test An acoustic test; one of the simplest methods used to detect damage
in bonded parts
 The most common instrumental NDT method used on composites
An ultrasonic tester is useful for detecting internal damage such as
Ultrasonic Inspection delamination's, core crush, and other subsurface defects
Two common methods of ultrasonic testing include the pulse echo and
through transmission methods