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Composite Materials and it’s

Application in Aerospace

Guided Presented
By By
Prof. Shivshekar.M Mallappa.IG
(3GN06ME033)
Contents
 Introduction.
 Definition of Composite Materials.
 Overview of Composite Materials.
 Composite Materials.
 Classification of Composite Materials.
 Fabrication.
 Composite Materials for Aerospace.
 Use of composites in aerospace structure.
 Materials for aerospace composites.
 Manufacturing /Construction Process.
 Advantages and disadvantages of Composite Materials.
 Applications.
 Conclusion.
Introduction
 Composite materials are particularly attractive to aviation and aerospace
applications because of their exceptional strength and stiffness-to-density
ratios and superior physical properties.

 As the technology matured, the use of composite materials for primary

structures such as wings and fuselages has increased. Initial applications of


composite materials to aircraft structures were in secondary structures
such as fairings, small doors and control surfaces.

 With their unique combination of properties such as low weight, high

strength, low flammability, smoke density and heat release, non-toxicity

and durability, composites are ideal for many aerospace applications, both

for interior and exterior components.


Definition of Composite Materials

Two or more inherently different materials that when combined together


produce a material with properties that exceed the constituent materials.

A composite material typically consists of relatively strong,


stiff fibres in a tough resin matrix.

The properties of the composite are superior and possibly


unique in some specific respects to the properties of individual
components
Overview of Composite Materials
• Composites are essentially plastics reinforced with carbon

fibres.

• Emergence of strong and stiff reinforcements like carbon


fibre along with advances in polymer research to produce
high performance resins as matrix materials have helped
meet the challenges posed by the complex designs of
modern aircraft.
Composite Materials
1 .Composite materials can provide a much better strength-to-weight ratio than any
metals.

2. Carbon fibres, each no larger than a human hair, are set into resin to form sheets.

Covering
with Resin Fibres’s layer
matrix to
form sheets
Layers of a Composite Tube

Each color represents a different fiber orientation and


change in material properties relative to the Global
Axis.
Modeled Tube in ANSYS

Simple model of composite material


with co-ordinate system.
Classification of Composite
Materials
Reinforcement
•Particulate.
•Fiber.
•Structural.

Matrix
•Polymer.
•Metal.
•Ceramics.
Matrix Considerations
 End Use Temperature

 Toughness

 Cosmetic Issues

 Flame Retardant

 Processing Method

 Adhesion Requirements
Reinforcement for Composites

Different types of reinforcement for composites:


(a) particle reinforcement;
(b) short fiber reinforcement;
(c) continuous fiber reinforcement;
(d) laminate reinforcement.
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Fabrication

Manufacturing engineers are, similarly, wrestling with


unfamiliar difficulties. Problems with wrinkling of the fibres
in the fabrication process, resulting in a loss of stiffness and
strength in the finished component.
Different Composites
(a) Transverse section
of a boron fiber reinforced
aluminum composite.

(b) Section of a short


alumina
fiber/aluminum matrix
composite.

(c) Deeply etched transverse


section of a composite.
Polymer Matrix Composite(PMC)

PMC’s also have excellent anti-corrosion and anti-chemical properties.


These are inherent to atmospheric weathering changes, do not absorb
moisture and also has excellent aesthetic appearance.
Real Test on Composite Tube

Hydraulic testing machine for composites.

Composite Tube
Composite Materials for Aerospace
Composite materials are ideal for many aerospace
applications, both for interior and exterior components.

composite materials for V-22 military helicopter


Use of composites in aerospace structure
With their unique combination of properties, like
low weight,
high strength,
low flammability,
 smoke density,
 heat release,
Fatigue-resistance,
corrosion -resistance ,
 non-toxicity and
durability.
Aerospace programmes use significant
amount of composites as highlighted in the
figure below.
Carbon Fibers Used
Increased Carbon Epoxy
in Wing and Tail Skins.
Usage in Centre.

High Strength/Durability
steel, Used in Improved Toughness
Resin . Used in
and Flap Transmissions. All Structural
Materials for aerospace composites
Fibre Application areas
Glass Small passenger a/c parts, air-craft interiors,
E-glass secondary parts; Radomes; rocket motor casings
S-glass Highly loaded parts in small passenger a/c.
Aramid
Fairings; non-load bearing parts
Low modulus
Radomes, some structural parts; rocket
Intermediate
motor casings
modulus
Highly loaded parts
High modulus
Carbon
Standard modulus Widely used for almost all types of parts in a/c,
(high strength) satellites, antenna dishes, missiles, etc.
Intermediate Primary structural parts in high performance
modulus fighters
High modulus Space structures, control surfaces in a/c
Ultra-high strength Primary structural parts in high performance
fighters, spacecraft
Manufacturing /Construction Process

Airbus A380

Main body under


construction using
carbon epoxy and
polymer matrix
composite .
Concerns with composite usage and
proven aesthetic appearance

Airbus A380

Light-weight due to high specific strength and stiffness.


 Fatigue-resistance and corrosion resistance .
Capability of high degree of optimization : tailoring the directional
strength and stiffness.
Advantages of Composite Materials
The most salient aspect of composite material is extremely
high specific strength and modules .
Raw materials for PMC’s are easily available and hence can
be produced at lower cost, if only large scale demand
ensured.
PMC’s have excellent anti-corrosion and anti-chemical
properties.
Tensile strength of carbon/epoxy 1830 Mpa, due to which it
can withstand for erosion and adopt to cover the main body
of air crafts.
Disadvantages of Composite Materials

Cost of part made from graphite/epoxy may cost 10 to 15 times more


than
conventional materials.
Debonding, delamination ,fibre full out etc are some of the major
problems
 Many times non-destructive testing fails to detect the cracks, fibre full
out .
Repair of cracks/flaws is not simple as in the case of metals.
Recycling of composites is still a major issue.
Applications of composite Materials

In aircraft, missiles & space sectors.


Marine Applications.
Automobile Applications.
Applications in Electronics.
Sports goods.
Conclusions

Composite materials offer endless design options.


Matrix, Fiber and Perform selections are critical in the
design process.
Structures can be produced with specific properties to
meet end use requirements.
Composite materials have high strength to weight ratio.
So they are best suited for various aerospace
applications.
References
1. Anon, “ A Brief Look at Composite Materials in Airbus Commercial Aircraft”,
High
Performance Composites March/April 1999.
2. Heth, Jenny, “Helicopter Industry Designs for Composites”, High Performance
Composites May/June 2000.
3. Mezzadri, Jean-Claude, “Aerospace Composite Materials are Mature”, SAMPE
Europe
Opening Session 1999.
4. Anon, “Materials in the Current Air Force”
5.M. Schwartz, Composite Materials Handbook, Chap. 1
6.T.W. Chou, Structure and Properties of Composites, Chap.1
7. P.K. Mallick (Ed.), "Composite Engineering Handbook", Marcel Dekker,
Inc.
(1997)
8. S.R. Swanson, "Advanced Composite Materials", Prentice-Hall, Inc.
(1997)
9. D. Hull and T.W. Clyne, "An Introduction to Composite Materials",
Cambridge
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