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COMPOSITES
INTRODUCTION
CHRISTIAN
What is Composite:
The term composite is used to describe two or
more materials that are combined to form a
much stronger structure than either material by
itself.
The most simple composite is composed of the
elements: a matrix (fabric) which serves as a
bonding substance (adhesives or resins), and a
reinforcing material. Prior to combination, the
matrix is generally in liquid form and the
reinforcing material is a solid. When the
substances are combined and cured, the part is
stronger than fabric is by itself, and stronger
than the resin is by itself.
Modern composites are advanced to the point
that they are strong enough to be used in
primary airframe components like rudders
and floor beams. In some cases the whole
airframe is designed of advanced composite
materials. Composites are used because
overall properties of the composites are
superior to those of the individual
components. While the structural value of a
bundle of fibres is low, the strength of
individual fibres can be harnessed if they are
embedded in a matrix that acts as an
adhesive, binding the fibres together and
lending solidity to the material.
The rigid fibres impart structural strength
to the composite, while the matrix
protects the fibres from environmental
stress and physical damage and imparts
thermal stability to them. The fibre-matrix
combination also reduces the potential for
a complete fracture; if one fibre fails the
crack may not extend to other fibres,
whereas a crack that starts in a monolithic
(or single) material generally continues to
propagate until that material fails.
Most conventional composites resemble plywood in
that they are built in thin layers, each of which is
reinforced by long fibres laid down in a single
direction. Such materials exhibit enhanced strength
only along the direction of the fibres. To produce
composites that are strong in all directions, the fibres
are woven into a three-dimensional structure in which
they lie along three mutually perpendicular axes.
. Composites are of greatest use in the aerospace
industry, however, where their stiffness,
lightness, and heat resistance make them the
materials of choice in reinforcing the engine
cowls, wings, doors, and flaps of aircraft.
Composite materials are also used in rackets and
other sports equipment, in cutting tools, and in
certain parts of automotive engines.
TYPES OF COMPOSITES
MAC
Polymer-matrix composites
CHRISTIAN
Advantages
High strength to weight ratio (low density high
tensile strength)
High tensile strength at elevated temperatures
High toughness
Light Weight
Chemical Resistance/ Corrosion resistance
Colour
Translucency
Design flexibility
Manufacturing economy
Expense
Application
Processability
Reduction of parts and fasteners
Fire resistant
Disadvantages
General expensive
Not easy to repair
MATERIALS
REINFORCING MATERIALS
General:
When combined with a matrix, the reinforcing material
(fibres) are what give the major strength to the
composite components. There are several types of
reinforcing fibres; the most commonly used are
outlined as follows:
Fibreglass – Fibreglass is made from small strands of
molten silica glass and then spun together and woven
into cloth. There are many different weaves of
fiberglass available, depending on the application. The
wide range of application of the material and its low
cost make it one of the most popular used. Fibreglass
weighs more and has strength than most other fibre
material.
Aramid – Aramid fibres are general characterized by
its yellow colour, light weight and its excellent tensile
strength. Aramid is a registered tradename of the Du
Pont Company and is an ideal material for aircraft
parts that are subject to high stress and vibration
(e.g. rotor blades). It is also used in bullet-proof-
vests. Damage to Aramid Structural components will,
in general, be repaired with fiberglass.
Graphite – Black graphite/carbon fibre is very strong
and stiff and is used for its rigid, strong properties.
This material is used to manufacture primary
structural components like ribs and floor beams.
Graphite is stronger in compressive strength than
Kevlar. however it is more brittle than Kevlar. It has
the problem of being corrosive when bonded to
aluminium.
MATRIX MATERIALS
General:
The matrix is the bonding material the completely
surrounds the fibre to give strength and transfer the
stress to the fibre. The newer matrix materials have
good stress-distribution, heat resistant, chemical
resistant and durability properties. Most of these
newer matrix materials are epoxy resins.
Resin matrix are two-part systems consisting of a
resin and a hardener or catalyst, which acts as
curing agent.
Resinsare a type of plastic and are broken
down into two categories:
Thermoplastic
Thermoset
Thermoplastic – Thermoplastic resins use heat
to form the part into a specified shape, and this
shape in not permanent. That means, if we add
heat again it will flow again to another shape.
So Thermoplastics can only be used in areas
where the temperature do not exceed 750°F.
Thermosets – Thermoset use heat to form and
set the shape permanently. The plastic, once
formed, cannot be reformed even if it is heated.
Most composite structural components are
made from thermoset resins.
Epoxy Resins – Epoxy resins are one type of
thermosetting plastic resin. They have good
adhesion, strength and resistance to
moisture and chemical properties. They are
used to bond non-porous and dissimilar
materials, like metal to composite
components.
Prepeg – Prepeg is the abbreviation of pre-
impregnated fabrics, and they are fabrics
that have the resin already impregnated into
them.
USES
CHOOSING MATERIALS
MAC
For Matrix:
For the matrix, many modern composites
use thermosetting or thermosoftening plastics (also
called resins). (The use of plastics in the matrix
explains the name 'reinforced plastics' commonly
given to composites). The plastics are polymers that
hold the reinforcement together and help to determine
the physical properties of the end product.
Thermosetting plastics are liquid when prepared but
harden and become rigid (ie, they cure) when they
are heated. The setting process is irreversible, so that
these materials do not become soft under high
temperatures. These plastics also resist wear and
attack by chemicals making them very durable, even
when exposed to extreme environments.
Thermosoftening plastics, as the name implies,
are hard at low temperatures but soften when
they are heated. Although they are less
commonly used than thermosetting plastics they
do have some advantages, such as greater
fracture toughness, long shelf life of the raw
material, capacity for recycling and a cleaner,
safer workplace because organic solvents are not
needed for the hardening process.
Ceramics, carbon and metals are used as the
matrix for some highly specialised purposes. For
example, ceramics are used when the material is
going to be exposed to high temperatures (eg,
heat exchangers) and carbon is used for products
that are exposed to friction and wear (eg,
bearings and gears).
For Reinforcement:
Although glass fibres are by far the most common
reinforcement, many advanced composites now use
fine fibres of pure carbon. Carbon fibres are much
stronger than glass fibres, but are also more
expensive to produce. Carbon fibre composites are
light as well as strong. They are used in aircraft
structures and in sporting goods (such as golf clubs),
and increasingly are used instead of metals to repair
or replace damaged bones. Even stronger (and more
costly) than carbon fibres are threads of boron.
Polymers are not only used for the matrix, they
also make a good reinforcement material in
composites. For example, Kevlar is a polymer
fibre that is immensely strong and adds
toughness to a composite. It is used as the
reinforcement in composite products that
require lightweight and reliable construction
(eg, structural body parts of an aircraft).
Composite materials were not the original use
for Kevlar – it was developed to replace steel in
radial tyres and is now used in bulletproof
vests and helmets.
WORKING WITH COMPOSITE
MATERIALS
Safety
MAC
General:
Damage Evaluation
A complete inspection of the damaged area or
component will give the required information
concerning the extent and type of damage.
Depending on the type, extent and importance
of the affected zone, the damage acceptance
level may be determined.
Acceptance Level
Abrasion
Scratches
Gouges
Nicks
Debonding
Delamination
Dents
Skin perforated damage includes:
◦ Lightning strikes
◦ Holes
◦ Impact by foreign object, requiring
investigation for delamination moisture
contamination.
Abrasion
General:
Recommended repairs can be of three
types:
◦ Temporary repairs
Permanent cosmetic repairs
Permanent structural repairs
PREPARATION BEFORE REPAIR
Tap Testing
Visual or Optical Inspection
Holography
Acoustic Emission
Ultrasonic
Radiography