Composite Facts Index

 

                                                                                               

Symbols and Abbreviations                                                             

Introduction                                                                                    

1. Materials                                                                                     

1.1 Fibers                                                                                   

1.1.1 General                                                                      

1.1.2 Various Types of Fibers                                                

1.1.3 Explanation of Terms                                                   

1.2 Matrix Materials                                                                     

1.2.1 Epoxy Resin                                                                

1.2.2 Polyester Resin                                                            

1.2.3 Vinylester Resin                                                           

1.2.4 Cure Cycles                                                                 

1.2.5 Chemical Resistance                                                     

1.2.6 Characteristics at Elevated Temperatures                        

1.2.7 Storage                                                                      

1.2.8 Curing Control                                                            

1.2.9 Example of Resin                                                         

1.3 Filler Materials                                                                       

1.4 Fabrics                                                                                  

1.4.1 Twodimensional Fabrics                                               

1.4.2 Threedimensional Fabrics                                             

1.4.3 Prepregs                                                                     

1.5 Release Agents                                                                    

 

2. Manufacturing Processes                                                            

2.1 Tools                                                                                    

2.2 Mixing Resin for the First Time                                                

2.3 Wet Layup                                                                             

2.4 Bonding                                                                                

2.5 Assembly of a Molded Airplane                                               

2.6 Moldless Construction                                                             

2.7 Sandwich Foam Cores                                                            

2.8 Vacuum Bagging                                                                    

2.9 Postcuring                                                                             

2.10 Molds                                                                                 

2.10.1 Simple Molds for Small Parts                                       

2.10.2 Wing Molds                                                               

 

3. Aircraft Structures and Components                                          

3.1 Fuel Tanks                                                                            

3.2 Glass Bearings                                                                       

3.3 Composite Trusses                                                                 

3.4 Spar Cap Manufacturing                                                          

3.5 Electrical System and Grounding                                              

3.6 Integration of Antennas                                                          

3.7 Bonding Canopies and Windows                                              

3.8 Access Panels                                                                        

3.9 Fire Resistance                                                                       

 

4. Finishing                                                                                      

4.1 Preparation                                                                           

4.2 Filling                                                                                   

4.3 Sanding                                                                                

4.4 Detailing                                                                               

4.5 Surface Finishing                                                                   

 

5. Sandwich Designs                                                                        

5.1 Basics                                                                                   

5.2 Core Materials                                                                       

5.2.1 Balsa Wood                                                                 

5.2.2 Foam                                                                         

5.2.3 Honeycomb                                                                

5.2.4 3D Fabric                                                                    

 

6. Repairs                                                                                        

6.1 How to Recognize Damage                                                     

6.2 How to Repair Damaged Parts                                                 

 

7. How to Design Composite Structures                                         

7.1 Loads                                                                                   

7.2 Bonding                                                                                

7.3 Load Transfer                                                                        

7.3.1 Bolted Connections                                                      

7.3.2 Load Transfer Examples                                               

7.3.3 Construction of Loops                                                  

 

8. Static Load Tests                                                                         

8.1 Material Design Data                                                              

8.2 Test Specimens                                                                     

8.3 Determining the Modulus of Elasticity                                       

8.4 Load Tests                                                                            

8.5 Safety Factors                                                                        

 

 

9. The Theory of Composites                                                          

9.1 What are Composites                                                             

9.2 Directional Properties                                                             

9.3 Free Breaking Lengths                                                            

9.4 Calculation of Roving Cross Sections                                        

9.5 Calculation of Spar Cap Cross Sections                                     

9.6 Calculation of Laminate Thickness                                            

9.7 Fiber Volume Fraction and Fiber Weight Fraction                       

9.8 How to determine Fiber Weight or Fiber Volume Fraction           

9.9 Twisting                                                                               

9.10 Rules for Laminate Schedules                                                

9.11 Buckling, an Instability Problem                                             

9.12 Factors that Influence Buckling                                              

 

Literature                                                                                           

 

Appendix 1

Tables with Material Properties, Design Values, Suppliers                                                    

                 

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