constituents core materials - mech.utm.my · aircraft composite structure repair core material...
TRANSCRIPT
![Page 1: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/1.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR
Constituents – Core Materials
Introduction to Composite Materials 1 ATA 51 - Aircraft Composite Repair
![Page 2: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/2.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
Core Material Properties
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 2
Core materials
Metallic
Aluminum
Non metallic
Honeycomb Foam Wood
![Page 3: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/3.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 3
LAMINATES
LAMINATE/
MONOLITHIC
STRUCTURE
LAMINA LAMINA
CORE
SANDWICH
STRUCTURE
Core Material Properties
![Page 4: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/4.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
Core Material Properties
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 4
![Page 5: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/5.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
• First used in 1940’s. – Nomex honeycomb – Typically Hexcel
HRH 10 • Meta aramid fiber with phenolic resin
– Kevlar N636 reinforced honeycomb • Para amid fiber with phenolic resin
– Glass fiber reinforced plastic honeycomb • Glass fiber with phenolic resin
– Aluminum honeycomb
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 5
Core Material Properties
![Page 6: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/6.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
U.O.M
Nomex HRH
GFRP Core
Kevlar N636
Aluminum Alloy 5052
Density Kg/m3
72 72 72 72
Compressive Strength MPa 2.8 3.86 4.2 2.79
Shear Strength in L Direction
MPa 1.7 1.72 1.9 1.97
Shear modulus in L-Direction
MPa 54 65.5 120 354
Shear strength in W direction
MPa 0.86 0.97 1.2 1.16
Shear modulus in W direction
MPa 29 36 65 173
Absorption in humidity % 4.4 1.7 <5 N/A
In use temp range 0C -55 ~ 135 -55 ~ 135 -55 ~ 135 -55 ~ 175 ATA 51 - Aircraft Composite Repair
Modulus to Composite Materials 6
Core Material Properties
![Page 7: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/7.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 7
Nomex HRH HRP Glass Kevlar N636
Advantages
Available with small cell size and low density High shear properties
+/-450 Fiber orientation
Good fatigue & impact strength
Tough Dimensioanl stability
Easy to Bond when dry Higher modulus and strength than NOMEX ®
2X modulus
Easy to form Higher strength
Formadable Low moisture
absorption Better hot wets
Fire resistant, self extinguish Good thermal and electrical insulation up
to 1750C
25% weight reduction over GFRP
core
Good thermal and electrical insulation up to 1300C
Low CTE up to 1500C
Drawbacks High Prices
Water migration
Core Material Properties
![Page 8: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/8.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 8
Core Material Properties
Manufacturing honeycomb core
![Page 9: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/9.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
Core material properties
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 9
HRH10 – 1/8 – 3.0
ECA – 3.2 - 48
Material Designation
Cell Diameter
Density
Expanding direction
![Page 10: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/10.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 10
Core Material Properties
![Page 11: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/11.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 11
Core Material Properties
• Rigid • Curvature is
perpendicular to the ribbon direction
• Easy to form complex curve.
• Provide higher shear strength.
• Facilitate curving in L direction.
• Have higher ‘W’ shear properties and decrease ‘L’ shear properties.
![Page 12: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/12.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 12
Core Material Properties Lowly
loaded part
Sandwich Structure
Highly loaded part
Monolithic Structure
![Page 13: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/13.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
• Saving in the maintenance of the aircraft
• Higher energy impact resistant
• No fluid ingress problem
• Bolted repair possible in panel area
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 13
Core Material Properties
• Best stiffness versus weight ratio
• Good twisting stiffness
• Excellent thermal insulation
• Excellent acoustic damping properties
Monolithic Structure Sandwich Structure
Advantages
![Page 14: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/14.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
• Heavy if compared to sandwich structure
• Heavy weight ratio to stiffness
• Necessity of stiffening structure for twisting and compression resistance
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 14
Core Material Properties
• Sensitive to water ingress and various liquid agent
• Impact sensitive compared to monolithic
• Bolted repair are not recommended
Monolithic Structure Sandwich Structure
Drawbacks
![Page 15: Constituents Core Materials - mech.utm.my · AIRCRAFT COMPOSITE STRUCTURE REPAIR Core Material Properties ATA 51 - Aircraft Composite Repair Introduction to Composite Materials 2](https://reader031.vdocuments.mx/reader031/viewer/2022022607/5b86e8db7f8b9a2e3a8df03a/html5/thumbnails/15.jpg)
AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR
ATA 51 - Aircraft Composite Repair
Introduction to Composite Materials 15
Core Material Properties