Composite Materials and its Application in Aerospace

Guided By:

Presented By:MAYANK KUMAR MECH. ENGG 8TH SEM

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 .

As the technology matured, the use of composite materials for

primary structures such as wings and fuselages has increased. With their unique combination of properties composites are

ideal for many aerospace applications, both for interior and exterior applications..

Definition of Composite MaterialsComposite materials, often shortened tocompositescalledcomposition materials, areengineeredor naturally occurring materialsmade from two or more constituent materials with significantly differentphysicalorchemical properties which remain separate and distinct at themacroscopicor microscopic scale. A composite material typically consists of relatively strong, stiff fibres in a tough resin matrix. The properties of the composite are superior and unique in some specific

Overview of Composite Materials Plywood is a commonly encountered

composite material in our daily life.

Composite Materials1 .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 matrix to form sheets

Fibress layer

Layers of a Composite Tube

X

Each color represents a different fiber orientation and change in material properties relative to the GlobalAxis.

ANSYS simulation of carbon fiber and anisotropic materials

Modeled Tube in ANSYS

Simple model of composite material with co-ordinate system.

Classification of Composite Materials Reinforcement Particulate.Fiber. Structural.

MatrixPolymer. Metal. Ceramics.

Matrix Considerations End Use TemperatureToughness 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.

12

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

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)

PMCs also have excellent anti-corrosion and anti-chemical properties. These are inherent to atmospheric weathering changes, do not absorb moisture and also has excellent

eal Test on Composite TubeHydraulic testing machine for composites.

Composite Tub

Composite Materials for Aerospace Composite materials are ideal for manyaerospace applications, both for interior and exterior components.

composite materials for V-22 military helicopter

Use of composites in aerospace structureof properties, l their unique combinationlow weight, high strength, low flammability, smoke density, heat release, Fatigue-resistance, corrosion -resistance , non-toxicity and

Aerospace programmes use significant amount of composites as highlighted in the figure belowFibers Used Carbon.

Increased Carbon Epoxy Usage in Centre.

in Wing and Tail Skins.

High Strength/Durability steel, Used in and Flap Transmissions.

Improved Toughness Resin . Used in

terials for aerospace composi

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 A380Light-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 MaterialsThe most salient aspect of composite material is extremely high specific strength and modules . Raw materials for PMCs are easily available and hence can be produced at lower cost, if only large scale demand ensured. PMCs have excellent anti-corrosion and antichemical 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 MaterialsCost 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 MaterialsIn aircraft, missiles & space sectors. Marine Applications. Automobile Applications. Applications in Electronics. Sports goods.

Conclusion sComposite 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.

References1. 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

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