Composite:-

Composite:-
The term composite is used to describe two or more materials
that are combined to form a structure that is much stronger
than the individual components.
 Combination of Composite
 Matrix – that serves as a bonding substance. Generally in liquid form.
 Reinforcing Material – generally in solid form.
 Many time Core Materials are also added.

Reinforcing Fibers
 Fiber Glass (Glass cloth)
 Aramid / Kevlar
 Carbon / Graphite
 Boron
 Ceramics

 Fiber Glass (Glass cloth)

 Made from small strands of molten silicon glass that is span together and woven into
cloth.
 Wide spread availability and its low cost make fiber glass one of the most popular re-
enforcing fibers.
 White gleaming cloth.
 Weight more than other fibers but has less strength.
 Used for nonstructural application.
 Types of fiber glass:
 E - Glass
 E - Glass also known as “Electric Glass” for its high electrical resistance.
 It is a borosilicate glass commonly used for re-enforcement because of its
low cost and good strength characteristics.

 S - Glass
 It is a magnesia – alumina – silicate glass that is up to 40 percent
stronger that E-Glass and retains its strength characteristics at higher
temperature.
 S – Glass is used were a very high tensile strength fiber glass is needed.

 C – Glass is used in materials that require chemical resistance.

 T – Glass: Has high Thermal resistance.
 A – Glass: Use to make Bottles.
 Aramid / Kevlar
 yellow color, light weight, tensile strength and remarkable flexibility.
 It has a tensile strength approximately four times that of aluminum alloy.
 Use in aircraft parts that are subject to high stress & vibration.
 It does not have as much as compressive strength as carbon/graphite composite.
 Difficult to drill or cut – use brad point drill to drill & steel scissor to cut the
Aramid.
 Bullet proof according to the grade.
 Example: Kevlar 49 – Structural grade, Kevlar 129 – is bullet proof material & Kevlar
29 – is used for boats.
 Carbon / Graphite
 This black color fiber is very strong, stiff and used for its rigid
strength characteristics.
 Electrically conductive, low thermal expansion coefficient,
high fatigue resistance & having less impact resistance.
 Used to fabricate primary structural components such as ribs
& wing skin.
 It is stronger in compressive strength than Kevlar but it is
more brittle.
 It has the problem of being corrosive when bonded to
aluminium. (Use fiber glass coating to prevent corrosion.)
 Boron
 It is made by depositing the element boron into a thin filament of
tungsten.
 It has excellent compressive strength and is extremely hard.
 Boron composite have very high strength & stiffness in tension,
compression & bending stresses.
 Ceramic
 Ceramic fibers are used when a high temperature application is
needed.
 It retains most of its strength at temp. up to 2200°F.
 Used for tiles on firewalls in engine.
 Dissipates the heat quickly.
 Fiber orientation
 Some of the terms used to describe fiber orientation are:
 Warp: Runs along the length of fabric.
 The warp direction is designated at 0°.
 Take tensile load.
 Composite is considered strongest in warp direction.
 Weft (Fill): Runs perpendicular to warp fibers.
 They are designated as 90°.
 Bias: runs at 45° angle to the warp thread.
 Contoured shape can be formed by using bias.
 Selvage Edge: Prevent the edges from raveling is referred to as the selvage edge.
 1. Unidirectional: Fiber orientation in which all of
the major fibers run in one direction.
 Giving strength in run direction.
 2. Bidirectional or Multidirectional: Fibers to run
in two or more directions.
 Gives more strength in warp direction.
 3. Mats: Chopped fibers that are compressed
together by heat & pressure are called Mats.
 Not commonly used in repair work.
 Used for nonstructural application.
 Matrix Materials
 Matrix is a bonding material that completely
surrounds the fiber giving extra strength.
 Matrix are two part system – a Resin & a Catalyst, or
Hardener which act as curing agent.
 Matrix systems are type of plastic.
 There are two categories of plastic:
 Thermoplastic –Can be used again and again by using
heat.
 Thermoset - Use heat to force and set the shape of the
part permanently.
 Structural airframe application.
 Example – Epoxy Resin: Cowling & Aileron.
 Combination of two or more fiber / composite is called
hybrid.
 There are three common types of hybrid structures
used in aviation today.
 1. Intraply Hybrid: Reinforcing material that is woven
from two or more different fibers.
 2. Interply Hybrid: Two or more layers of different
reinforcing material that are laminated together.
 3. Selective Placement: Fibers may be placed to give
greater strength, flexibility or reduced cost.
Intraply Hybrid Interply Hybrid
 Epoxy Resin System
 Epoxy Resins are type of thermo setting plastic resin well known
for their outstanding adhesion, strength,resistance to moisture
and chemicals.
 Epoxy resins are resistance to deterioration by water, acids, bases
many chemicals solvents.
 Working with resin and Catalyst (accelerating member)
 Mix resins in proper ratios.
 Mix resins for proper amount of time, do not mix too fast.
 Pot Life: is the amount of time that the mixed resin will be
workable.
 Shelf Life: is the time the product is good in an unopened
container.
 Too much resin is used the part is called resin rich – affects
strength, make part brittle, adds extra weight.
 Fillers
 Fillers are thixotropic agent are materials that are added to resins to
control viscosity & weight, to increase profile & strength & to make resin
easier application.
Types of Fillers
1.Micro Balloons–
are small spheres of
plastic or glasses.
2.Chopped fibers or
flox – type of fiber
cut into a desired
length.
 Pre-impregnated Materials
 Pre-impregnated materials are fabrics that have the resin system already impregnated into the
fabric.

 Advantages of the Pre-Pregs

 The pre-preg contains the proper amount of matrix.
 The re-enforcing fibers are completely encapsulated with the matrix.
 Pre-preg fabric eliminates the use to manually weigh and mix components.
 Pre-preg materials produce a stronger component or repair.

 Disadvantages of the Pre-Pregs

 Many pre-pregs must be stored in a freezer.
 Pre-pregs material is much more expensive than raw fabric that can be impregnated with the resin
system.
 Core Materials
 It is the central member of an assembly.
 Types of Core Materials
 Honeycomb
 Foams
 Wood Core - Balsa wood or laminations of hard wood.
 1. Honeycomb
 Shape of natural honeycomb.
 High strength to weight ratio.
 High compression strength.
 Uniform distribution of stress.
 Rigidity, thermal & insulation.
 Fire resistant.
 Most common hexagonal shape.
 2. Foam
 Styrofoam
 Used on home-built aircraft & only with
 epoxy resin.
 Hot wire cutter is used to cut it.
 Urethane
 Used with either epoxy or polyester resin.
 Cannot be cut with hot wire cutter.
 Cut with number of common tools like knives.
 Poly Vinyl Chloride (PVC)
 Used with either epoxy or polyester resin.
 Hot wire cutter is used to cut it.
 Manufacturing Methods of
Composite
 Compression Molding – used to
manufacture a large number of
precision formed parts.

Vacuum Bagging – can apply

pressure to both very large & very
complicated shapes.
 Used in both repair &
manufacturing composite.

 Filament Winding – widely used

because low material cost, accuracy,
automation & repeatability.
 Used to produce strongest
composite structure such as
propeller, helicopter rotor blade &
fuselage.
 Fiber Placement, Tape Laying
 automated process, similar to
filament winding, very expensive.

 Resin Transfer Molding (RTM)

– uses two part mold.
Timesaving over hand lay up.
 Pultrusion –simple
& low cost
automated method.

 Do not require
vacuum bagging or
autoclave.

 Wet Lay-Up or
Hand Lay-Up –
laying prepreg
material by hand into
mold.
 Methods of Applying Pressures
 Shot(Heavier) bags
 Clecos
 Spring Clamps
 Vacuum Bagging
 Shot(Heavier) Bags
 Bag Filled with heavy material.
 Weight of bag provides the pressure.
 Effective when working on large
contoured surface.
 Cannot apply pressure to the
underside of an aircraft part.
 Clecos
 Used in conjunction with pre-shaped
cauls plates to apply pressure to the
repair.
 Spring Clamps
 This should be used to distribute
pressure evenly over area.
 Allow the pressure to continue even
after the resin flow.
 Vacuum Bagging
 The most effective method of applying pressure to a repair and is recommended for the
use whenever possible
 Vacuum Bagging Process
 Once the repair is made and the patches in place, the area is covered with a parting film
or a parting fabric (peel ply)
 A bleeder material is an absorbent material that is either placed around the edges.
 A breather material is placed on one side of the repair to allow air to flow through it and
up through the vacuum valve.
 The two vacuum valves are placed on top of the breather material to remove the air from
inside the vacuum bag.
 The bagging film should be slightly pressed into the tape until it forms an airtight seal
that covers the part.
 A sealant tape is attached around the edges of the repair.
 Vacuum bagging film is laid out the repair area and the edges are worked out into the
sealant tape to produce an airtight seal.
 The bagging film should be slightly pressed into the tape until it forms an airtight seal
that covers the part.
 A slit is cut into the bagging film over the vacuum base, and then the vacuum valve is
inserted into the base and sealed airtight.
 The vacuum source is connected to the vacuum hose and turned on.
 Vacuum Leak Check
 It is done to make sure the bag is sealed properly.
 Vacuum bagging Films
 Vacuum bagging films are used to cover the components and seal out air.
 Sealant Tape
 Are used to maintain a positive seal between the surface of the original part and the
bagging films.
 Peel Ply
 A nylon or polyester release fabric may be used next to the wet resin during operation
to transfer excess resin to the bleeder material without sticking to the part.
 Used to apply pressure, remove excess resin, and give feathered surface for painting.
 Bleeders
 Bleeders are cotton like absorbent material used to soak up excess resins.
 Breathers
 Are cottony materials that allow air to flow through a valve or over the surface of the
part throughout the vacuum – bagged area.
 Same material as bleeder.
 Used over repair area & under the vacuum bagging film.
 Methods of Curing
1.Room Temperature Curing
2.Heat Curing
3.Step Curing
4.Hear Blanket
5.Heat Lamps
6.Oven Curing
 Classification of damage:
 Cosmetic Defects – a defects on the outer surface that
does not involve damage to the structural reinforcing
fibers.
 Impact Damage – occurs when a foreign objects strikes
the part.
 Delamination – is the separation of fabric layers of
materials in a laminate.
 Cracks– occur in advanced composite structures just as
in metallic ones.
 Hole Damage– occur from impact, over-torquing
fasteners, or a result of fasteners pull-through.
 1. Visual Inspection-used to detects cracks, surface
irregularities and surface detects such as
delamination and blistering.
 A light, magnifying glass & small microscope is
useful.
 2. Coin tap test-one of the most important tools
used to detect internal flaws or delamination.
 Use a coin or rounded edge steel washer to tap
lightly along a bond line or on suspected areas.
 A sharp sound – good bond.
 Dull thud(sound) – bond separation.
 3. Ultrasonic Inspection – uses a high frequency sound
waves.
 Used to detect internal flaws.
 4. Thermography – Locates the flaws by temperature
variations.
 5. Laser Holography – Used to detect disbonding or water
in honeycomb & impact damage.
 6. Radiography – Used to detect cracks that cannot be
visually detected, both internally & externally.
 Used to detect water inside the honeycomb core cell.
 7. Hardness Testing – Hardness testers such as Barcol
Tester can be used to determine whether the resins have
reached their proper strength.
 Does not test the strength of composite, only the Matrix
strength.
 Water in honeycomb is detected by laser holography,
radiography & ohm meter.
 Composite Repair
 Repairs types:
Bolted or Bonded composite patches:-
Bolted or Bonded on surface patches are not preferred
because the repair may not restore the parts original
strength.
Resin Injection:-
Resin Injection is used to fill holes or voids.
Laminating on new repair plies:-
The most reliable type of repair is laminating on new
repair plies.
 Most common reasons for repair to fail are:
 Poor surface preparation.
 Contamination of fabric or other materials.
 Incorrect measuring & mixing of the resin system.
 Incorrect cure time, incorrect temperature, or
inappropriate temperature rise & drop.
 Inadequate pressure.
 For cleaning composite Methyl Ethyl Ketones (MEK) is
mostly used.
 Acetone is also used for cleaning composite.