Care and Repair of Advanced Composites

Name: Care and Repair of Advanced Composites
Brand: SAE International
Price: 354.99 EUR
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Keith B. Armstrong William Cole Eric Chesmar Francois Museux(Author)

SAE International (Publisher)

1st Edition

Published on 30. December 2020

562 pages

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978-0-7680-9316-2 (ISBN)

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CHAPTER 1 Introduction to Composites and Care of Composite Parts
1.1 Definition of Composites
1.2 History of Composite Materials
1.3 Advantages and Disadvantages of Composites
1.3.1 Advantages of Composites
1.3.2 Disadvantages of Thermosetting Resin Composites
1.3.3 Advantages of Thermosetting Resin Composites
1.3.4 Advantages of Thermoplastic Resin Composites
1.3.5 Disadvantages of Thermoplastic Resin Composites
1.4 Applications of Composites to Modern Aircraft, Yachts, Cars, and Trains
1.4.1 Early Aircraft Structures
1.4.2 Modern Aircraft Structures and Other Applications
1.4.3 Projected Use of Composites
1.5 Care of Composite Parts
1.5.1 Sources of Damage to Composite Parts
1.5.1.1 Physical or Chemical Damage
1.5.1.2 Deterioration in Normal Service
1.5.2 Avoidance of Damage and Reduction of Deterioration in Service
References
CHAPTER 2 Materials
2.1 Fiber Reinforcement
2.1.1 Comparison of Some High-Performance Fibers and Common Metals
2.1.2 Glass Fiber
2.1.2.1 Glass Manufacture
2.1.2.2 Glass Fiber Manufacture
2.1.3 Carbon Fibers
2.1.3.1 Carbon Fiber Manufacture
2.1.3.2 Future Development
2.1.3.3 Further Details of Carbon and Graphite Fibers
2.1.4 Aramid Fibers
2.1.5 Boron Fibers
2.1.6 Other New Fibers
2.2 Forms of Reinforcement
2.2.1 Tapes
2.2.2 Fabrics
2.2.2.1 Woven Fabric Weave Styles
2.2.2.2 Effect of Weave Style
2.2.2.3 Non-crimp Fabrics
2.2.2.4 Nonwoven Randomly Oriented Mats
2.2.2.5 Fiber and Fabric Glossary
2.3 Fiber Sizing and Finish
2.3.1 Glass Fiber Finishes
2.3.2 Carbon Fiber Finishes
2.3.3 Aramid Fiber Finishes
2.3.4 Sizing and Finish for New Types of Fibers and Fabrics
2.4 Matrix (Resin) Systems
2.4.1 Thermoplastic Composites
2.4.1.1 Early Applications
2.4.2 Thermosetting Resins
2.4.3 Properties Required of Matrix Resins and Adhesives
2.4.3.1 Physical and Chemical Properties
2.4.3.2 Mechanical Properties
2.4.3.3 Epoxy-Based Matrix Resins and Adhesives for Aerospace Use
2.4.4 Epoxy and Phenolic Pre-pregs and Film Adhesives: Curing Stages
2.4.5 Mixing and Mix Ratios for Epoxy Wet Resins
2.4.5.1 Weighing
2.4.5.2 Mixing
2.4.5.3 Definitions Related to Mixing and Application
2.4.6 Polyester Resins
2.5 Adhesives
2.5.1 Liquid and Paste Adhesives
2.5.2 Foaming Adhesives
2.5.3 Film Adhesives
2.5.4 Glue-Line Thickness Control
2.5.5 In-Service Effects on Resin Systems
2.6 Core Materials
2.6.1 Wood
2.6.2 Foam Core Materials
2.6.2.1 Material Types
2.6.2.2 Foam Density
2.6.2.3 Advantages and Disadvantages
2.6.3 Honeycomb Core Materials
2.6.3.1 Honeycomb Material Types
2.6.3.2 Cell Shapes
2.6.3.3 Honeycomb Densities and Cell Sizes
2.6.4 Fluted Core
2.6.5 Syntactic Core
2.7 Syntactic Foams and Potting Compounds
2.7.1 Filler Materials for Potting Compounds, Resin Systems, and Adhesives
2.7.2 Other Fillers
2.8 Protective Coatings
2.8.1 Sealants
2.8.1.1 Old-Generation Thiokol Sealants
2.8.1.2 New-Generation Polythioether Sealants
2.8.1.3 Silicone Sealants
2.8.1.4 Viton Rubber Sealants
2.8.2 Primers
2.8.3 Finishes
2.8.4 Conductive Coatings
2.8.5 Erosion-Resistant Coatings
2.8.6 Other Protective Coatings
References
Bibliography
CHAPTER 3 Handling and Storage
3.1 Shipping and Receiving
3.2 Temperature Requirements
3.3 Storage Practices
3.3.1 Temperature Requirements
3.3.1.1 Dry Fabrics
3.3.1.2 Storage of Pre-preg, Film, and Paste Adhesives, Potting Compounds, and Primers
3.3.1.2.1 Thermoplastic Resins and Their Composites.
3.3.1.3 Storage of Sealants for Aircraft Use
3.3.1.4 Storage of Consumable Items for Composite and Bonded Metal Repairs
3.3.2 Cleanliness and Damage Prevention
3.3.3 Moisture Damage Prevention
3.3.4 Identification
3.3.5 Release Notes and Approved Certificates
3.4 Shelf Life/Out-Time
3.5 Kitting
3.6 Recertification
3.7 Care of Materials in the Hangar or Workshop
CHAPTER 4 Manufacturing Techniques
4.1 Filament Winding
4.2 Lay-Up Methods for Fabrics and Tapes
4.2.1 Hand Lay-Up (Wet and Pre-preg Laminating)
4.2.2 Automated Lay-Up
4.3 Pultrusion
4.4 Resin Transfer Molding
4.5 Injection Molding
4.6 Tow Placement
4.7 Press Molding
4.8 Vacuum Bonding
4.9 Autoclave Bonding
4.10 Oven Curing
References
Other Useful Reading
CHAPTER 5 Original Design Criteria
5.1 Principal, Primary, and Secondary Structures
5.1.1 Sources of Damage to Composite Airframe Components
5.1.2 Consequences of Failure
5.2 Types of Composite Structures
5.2.1 Monolithic Laminated Structures (Solid Laminates)
5.2.2 Sandwich Structures
5.3 Ply Orientation
5.3.1 Warp Clock
5.3.2 Balance and Symmetry
5.3.3 Nesting and Stacking
5.4 Core Orientation and Other Design Characteristics
5.5 Operational Environment
5.5.1 Temperature
5.5.2 Humidity
5.5.3 Contaminants
5.5.4 Erosion
5.5.5 Thermal Stresses
5.5.6 Hygrothermal Effects
5.5.7 Fire Resistance
5.6 Electrical Requirements
5.6.1 Galvanic Corrosion
5.6.2 Electromagnetic Interference
5.6.3 Electrostatic Discharge
5.6.4 Lightning Strike Energy Dispersion
5.6.5 Radar Transmissivity
5.7 Mechanical Requirements
5.7.1 Tensile and Flexural Strength
5.7.2 Stiffness
5.7.3 Fatigue
5.7.4 Impact Resistance
5.7.5 Creep
5.8 Attachments/Joints
5.8.1 Bonded Joints
5.8.2 Mechanically Fastened/Riveted Joints
5.9 Other Design Requirements
5.9.1 Aerodynamic Smoothness
5.9.2 Weight and Balance
References
CHAPTER 6 Safety and Environment
6.1 Introduction
6.2 Workshop Conditions for Good Bonding
6.3 Respirable Fibers and Dust
6.3.1 Fiberglass
6.3.2 Carbon and Graphite Fibers
6.3.3 Aramid Fibers
6.3.4 Sanding Dust
6.4 Fumes and Vapors
6.4.1 Resin Fumes
6.4.2 Solvent Vapors
6.4.3 Sealant Vapors
6.4.4 Coatings
6.4.5 Fuel
6.4.6 Acid Fumes and Splash
6.4.7 Exposure Limits
6.5 Skin Contact
6.5.1 Fibers in Contact with the Skin
6.5.2 Resins in Contact with the Skin
6.5.3 Solvents in Contact with the Skin
6.5.4 Selection of Suitable Gloves
6.5.5 Skin Creams for Personal Protection
6.6 Material Safety Data Sheets
6.7 Exothermic Reactions
6.8 Waste Disposal
6.9 Safety Procedures
6.9.1 Emergency Action First-Aid Procedures
6.9.2 General Safety Procedures
6.9.3 Personal Safety Precautions
6.9.4 Dermatitis
6.10 Action in the Event of a Chemical Spillage
6.11 Explosion Risk
6.12 Static Discharge and Fire Prevention
6.12.1 Static Discharge Prevention
6.12.2 Fire Prevention
6.13 Safety Requirements for Electrical Appliances
6.14 ISO Environmental Management Standards
References
Bibliography
CHAPTER 7 Damage and Repair Assessment
7.1 Visual Inspection
7.2 Tap Test
7.3 Ultrasonic Inspection
7.4 X-Ray Methods
7.5 Eddy Current Inspection
7.6 Thermography
7.7 Bond Testers
7.8 Moisture Meters
7.9 Drying of Composites Prior to Repair
7.10 Interferometry/Shearography
7.11 Damage Types
7.12 Sources of Mechanical Damage
7.13 Damage Mapping
7.13.1 Assessment of Damage Significance
References
CHAPTER 8 Source Documents
8.1 Revision Systems
8.2 Effectivity
8.3 Drawing Numbering Systems
8.4 Internal Documents
8.5 Material and Process Specifications
8.6 Original Equipment Manufacturer Documents
8.7 Regulatory Documents
8.8 Airlines for America (formerly Air Transport Association of America) ATA 100 System
8.9 Aircraft Maintenance Manual
8.10 Component Maintenance Manual
8.11 Overhaul Manual
8.12 Illustrated Parts Catalog
8.13 Structural Repair Manual
8.14 Engine Manual
CHAPTER 9 Structural Repair Manual (SRM) Repair Method Selection
9.1 Component Identification
9.2 Damage Classification
9.2.1 Damage Terminology
9.2.2 Critical Areas
9.2.3 Allowable/Negligible Damage
9.2.4 Repairable Damage
9.2.5 Overhaul or Replace
9.2.6 Other Considerations
9.3 Repair Methods
9.3.1 Speedtape
9.3.2 Resin Sealing
9.3.3 Potted Repairs
9.3.4 Bolted Doublers (Metal Plates) and Bonded Doublers (Composite Patches)
9.3.5 Pre-cured Doublers Versus Co-cured Doublers
9.3.6 Room-Temperature Wet Lay-Up
9.3.7 Elevated-Temperature Wet Lay-Up
9.3.8 Pre-preg Repairs
9.3.9 Scarfed and Stepped-Lap Repairs
9.3.10 Composite Repairs to Metals
References
CHAPTER 10 Repair Techniques
10.1 Preparation
10.1.1 Paint Removal
10.1.2 Disbonding Methods
10.1.2.1 Disbonding Adhesively Bonded Metal Parts
10.1.2.2 Disbonding Composite Parts
10.1.3 Damage Removal
10.1.3.1 Damage Removal from Metal Parts
10.1.3.2 Removal of Skin and Doubler Material
10.1.3.3 Damage Removal from Composite Parts
10.1.3.4 Removal of Core Material
10.1.3.5 Removal of Surface Corrosion
10.1.4 Moisture and Contamination Removal
10.1.5 Surface Preparation of Composites: Repair Sanding and Ply Determination
10.1.5.1 Abrading
10.1.5.2 Taper Sanding/Scarfing
10.1.5.3 Step Sanding and Cutting
10.1.6 Water Break Test
10.1.7 Metallic Surface Preparation
10.2 Typical Repairs
10.2.1 Edge Band Repairs
10.2.2 Repair of Damage to Core and One Skin
10.2.3 Repair of Damage to Core and Both Skins
10.2.4 Hybrid Repairs
10.2.5 Blind Repairs
10.2.6 Injected Repairs
10.2.7 Solid Laminate Repairs
10.2.8 Potted Repairs
10.2.9 Metal-to-Metal Bonding
10.2.10 Plastic Welding (Solvent or Heat)
10.3 Adhesive Usage
10.4 Bagging Materials, Release Films, Release Fabrics, Peel Plies, Breather Cloths, Bleeder Cloths, Bleed-Out Fabrics, and Application Techniques
10.4.1 Terminology
10.4.2 Selection Criteria
10.4.3 Surface Versus Envelope Bagging
10.4.4 Pleating
10.4.5 Bagging Sequence
10.4.6 Vacuum Requirements and Principles
10.4.6.1 Vacuum Bonding
10.4.6.2 Application of Vacuum Pressure to Plates and Assemblies Using Nonperforated Honeycomb
10.4.6.3 Practical Techniques to Ensure Adequate Applied Vacuum Pressure to Parts under Repair
10.4.7 Caul Plate and Dam Usage
10.4.8 Vertical Bleed Method
10.4.9 Squeeze-Out (Edge Bleed-Out) Method
10.4.10 Zero-Bleed Method
10.4.11 Ply Compaction and Debulking
10.4.12 Debagging Precautions and Typical Problems
10.5 Curing Stages and Temperatures-Heating Techniques
10.5.1 Curing Stage Definitions
10.5.2 Low-Temperature Cure
10.5.3 Elevated-Temperature Cure
10.5.4 Direct versus Indirect Heating
10.5.5 Ramp Rates and Soak Cycles
10.5.6 Temperature Control and Monitoring
10.5.7 Thermocouple Placement
10.5.8 Temperature Control Problems
10.5.9 Hot Bonder and Heater Blanket Usage
10.5.10 Heat Sinks
10.5.11 Thermocouples
10.5.12 Distortion of Parts During Heating or Cooling
10.6 Post-Repair Inspection
10.7 Surface Restoration
References
CHAPTER 11 Mechanical Fastening Systems
11.1 Introduction
11.2 Fastener Types
11.2.1 Fastener Standards
11.2.2 Fastener Compatibility
11.2.3 Rivets
11.2.3.1 Solid Rivets
11.2.3.2 Blind Rivets
11.2.3.3 Hollow End Rivets
11.3 Screws, Nuts, and Bolts
11.3.1 Specialty Fasteners (Special Bolts)
11.3.2 Lockbolts
11.3.3 Hex Drive Bolts
11.3.4 Specialty Blind Bolts
11.4 Spacers, Bolt Inserts, and Grommets
11.5 Hole Preparation
11.5.1 Drilling
11.5.2 Hole Sizes and Tolerances
11.5.3 Edge Distance and Fastener Pitch
11.5.4 Hole Protection
11.6 Fastener Installation and Removal
11.6.1 Fastener Installation
11.6.2 Fastener Removal
11.7 Fastener Substitution
11.8 Bonded Fasteners
11.9 Composite Fasteners
References
CHAPTER 12 Documentation
12.1 Process Control Documents
12.1.1 Cure Chart/Data Strip
12.1.2 Routine and Nonroutine Work Documents
12.1.2.1 Routine Work Documents
12.1.2.2 Nonroutine Work Documents
12.1.3 Nondestructive and Destructive Inspection Data
12.1.4 Coupon Test Results
12.1.5 Clean-Room Temperature and Humidity
12.1.6 Return to Service/Logbook Sign-Offs
12.2 Calibration Records
12.3 Material Control Records
12.4 Component Documentation
12.5 Training Records
CHAPTER 13 Shop Equipment and Hand Tools
13.1 Hand Tools and Techniques
13.1.1 Drills
13.1.2 High-Speed Grinders
13.1.3 Cutting Utensils
13.1.4 Hand Routers
13.1.5 Orbital Sanders
13.1.6 Cast Cutter (Oscillating Saw)
13.1.7 Painting Equipment
13.1.8 Resin Applicators
13.2 Shop Equipment
13.2.1 Bandsaws
13.2.2 Air Compressors
13.3 Heating Devices
13.4 Measuring Devices
13.5 Health and Safety Equipment
References
CHAPTER 14 Tooling and Mold Making
14.1 Introduction
14.2 Caul Plate and Dam Fabrication
14.3 Splash Mold Making
14.4 Release Agents/Films
14.5 Simple Room-Temperature Tooling
14.6 Room-Temperature Curing Pre-Preg Tooling
14.6.1 Lay-Up
14.6.2 De-bulk Procedure
14.6.3 Final Bagging Procedure
14.6.4 Autoclave Cure
14.6.5 Time Limits
14.6.6 Step Post-Curing Procedure After Room-Temperature or Low-Temperature Initial Cure
14.6.7 Support Structures
14.6.8 Initial Release Priming of New Composite Tools
14.6.9 Developments in Low-Temperature Curing Materials
References
CHAPTER 15 Metal Bonding
15.1 Introduction
15.1.1 History and Requirements
15.1.1.1 Metal Bonding
15.1.1.2 Epoxy Adhesives
15.1.1.3 Requirements for Adhesives
15.1.2 Principles of Adhesion
15.1.2.1 Adhesion Theory
15.1.2.2 Environmental Durability
15.1.2.3 Temperature Effects
15.1.2.4 Humidity Effects
15.1.3 Advantages and Disadvantages of Metal Bonding
15.2 Surface Preparation Methods
15.2.1 Abrasive Cleaning
15.2.2 Semco Pasa-Jell Now Owned by PPG Industries
15.2.3 Hydrofluoric Acid Etching
15.2.4 Grit Blast/Silane
15.2.5 Alodine or Alochrom 1200
15.2.6 Sol-Gel Process
15.2.7 FPL Etch
15.2.8 Chromic Acid Anodizing
15.2.9 Phosphoric Acid Anodizing
15.2.9.1 Phosphoric Acid Containment System (PACS)
15.2.9.2 Phosphoric Acid Non-tank Anodizing (PANTA)
15.3 Other Surface Preparations
15.4 Primers
15.4.1 Reasons for Using Primers
15.4.2 Primer Types
15.4.3 Application of Primers
15.4.4 Curing/Drying
15.4.5 Thickness Verification
15.5 Handling Primers
References
Bibliography
CHAPTER 16 Design Guide for Composite Parts
16.1 Introduction
16.2 Analysis of Reports Received
16.3 Other Required Design Features Not Mentioned in the Analyzed Reports
References
CHAPTER 17 Repair Design
17.1 General Repair Design
17.1.1 Introduction to Repair Design
17.1.2 Laminate Loading
17.1.2.1 Tension and Compression Loads and Strains
17.1.2.2 Shear Stress and Strain
17.1.2.3 Poisson's Ratio
17.1.3 Repair Philosophy and Design Requirements
17.1.3.1 Certification Load Capacity
17.1.3.2 Repair Categorization
17.2 Laminate Repair Design
17.2.1 Introduction to Laminate Repair Design
17.2.2 Laminate Repair Design Considerations
17.2.2.1 Stiffness
17.2.2.2 Strength
17.2.2.3 Stability
17.2.2.4 Environmental Effects and Protection
17.2.2.4.1 Operational and Glass Transition Temperatures (T g).
17.2.2.4.2 Lightning and Electrostatic Protection.
17.2.2.5 Other Repair Design Considerations
17.2.2.6 Laminate Repair Recommendations
17.2.3 Laminate Analysis Techniques for Repair Design
17.2.3.1 Introduction to Simplified Analysis Techniques
17.2.3.2 Elastic Modulus (E) Analysis
17.2.3.3 Strength (F) Analysis
17.2.3.4 Poisson's Ratio (? 0) Analysis
17.2.3.5 In-Plane Shear Modulus (G)
17.2.4 In-Plane Shear Strength (t)
17.3 Core Repair Design
17.3.1 Function and Loading of Core in Sandwich Construction
17.3.2 Core Material, Density, and Cell Size
17.3.3 Core Repair Design Recommendations
17.4 Bonded Joint Repair Design
17.4.1 Introduction to Bonded Joints
17.4.2 Types of Bonded Joints
17.4.3 Failure Modes of Bonded Joints
17.4.4 Adhesive Behavior in Bonded Joints
17.4.4.1 Adhesive Shear Stress and Strain
17.4.4.2 Elastic and Plastic Adhesive Behavior
17.4.4.3 Temperature and Moisture Effects
17.4.4.4 Joint Adherend Effects: Stiffness Imbalance and Thermal Mismatch
17.4.4.5 Recommended Joint Overlaps and Simplistic Analysis
17.4.5 Adhesive Peel Stress and Displacement
17.4.6 Durability: Fatigue, Creep, and Environmental Effects
17.4.7 Bonded Joint Repair Considerations
17.4.8 Bonded Joint Repair Design Recommendations
17.5 Mechanically Fastened Joints
17.5.1 Introduction to Mechanically Fastened Joints
17.5.2 Fastened Laminate Failure Modes
17.5.3 Fastener Failure Modes
17.5.4 Open-Hole Stress Concentrations: Composites Versus Metals
17.5.5 Loading of Mechanically Fastened Joints
17.5.6 Loaded Fastener Holes
17.5.7 Fastener Load Distribution and Joint Geometry
17.5.8 Lay-Up Orientation for Fastened Joints
17.5.9 Pad-Ups and Hybrid Material Application
17.5.10 Fatigue of Fastened Composite Joints
17.5.11 Effects of Gaps and Shims
17.5.12 Fastener Selection
17.5.13 Mechanically Fastened Repairs in Sandwich Panels
17.5.14 Fastened Joint Repair Recommendations
References
Bibliography
About the Authors
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Care and Repair of Advanced Composites

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