Aircraft Materials, Construction & Repair II (AMCR) Activity 1 - PDF

AIR LINK INTERNATIONAL AVIATION COLLEGE Air Link Building, Domestic Road, Domestic Airport, Pasay City 1301 Philippines UNDERGRADUATE STUDIES DEPARTMENT...

AIR LINK INTERNATIONAL AVIATION COLLEGE Air Link Building, Domestic Road, Domestic Airport, Pasay City 1301 Philippines UNDERGRADUATE STUDIES DEPARTMENT First Trimester, A.Y. 2024-2025 Aircraft Maintenance and Construction and Repair II (Composites) AIRCRAFT MATERIALS, CONSTRUCTION & REPAIR II (AMCR) INSTRUCTOR: MR. JOHN BRAYN C. PARDALES ACTIVITY #1 NAME: Michael Angelo Sumook DATE: 09/02/24 Based on our conversation last week, please prepare a report covering the topics we discussed. Doing this exercise may help you with the quiz scheduled for tomorrow! USE YOUR OWN WORDS DEADLINE OF SUBMISSION: SEPTEMBER 3, 2024 TOPICS: LAMINATED STRUCTURE Composite materials consist of a combination of materials that are mixed together to achieve specific structural properties. The individual materials do not dissolve or merge completely in the composite but act together as one. Normally, the components can be physically identified as they interface with one another. These materials can be applied to aircraft structures like on its fairings, flight control surfaces, landing gear doors, interior components, stabilizers, propellers, and more. Types of Materials Isotropic These are materials that do not change with direction Example: Metal and glass. Anisotropic These are materials that change in perpendicular directions Example: Wood and composites. Orthotropic These are properties that change in all directions. Example: Wood and structure.  AIR LINK INTERNATIONAL AVIATION COLLEGE Air Link Building, Domestic Road, Domestic Airport, Pasay City 1301 Philippines UNDERGRADUATE STUDIES DEPARTMENT First Trimester, A.Y. 2024-2025 Aircraft Maintenance and Construction and Repair II (Composites) WHAT ARE THE MAJOR COMPONENTS OF COMPOSITES Major Components of Composites Fiber: The main component of the composite material that carries the load. The reinforcing material is solid. Matrix: The matrix supports and holds together the fibers to bond them with the composite material. Structural properties, such as stiffness, dimensional stability, and strength of a composite laminate, depend on the stacking sequence of the plies. Fiber Orientation The orientation sequence of the plies determines the stiffness and strength of a composite build. In advanced composite materials, selecting the ply orientation correctly is essential to producing a solid structural design. For the part to respond to axial loads, it might need 0° plies, ±45° plies for shear loads, and 90° plies for side loads. Warp Clock Warp: shows the longitudinal fibers of a fabric Warp Clock: Indicates the way the fibers are oriented on a manufacturer's sheet, spec sheet, or diagram. When the fabric comes off the roll, the orientation defaults to zero if the warp clock is not present on the fabric. Fiber Forms All product forms generally begin with spooled unidirectional raw fibers packaged as continuous strands. Filament: A single fiber. It can also be called a “strand”. Tows, Yarns, or Rovings: Bundles of filaments. Kevlar yarns are not twisted, fiberglass yarns are.  AIR LINK INTERNATIONAL AVIATION COLLEGE Air Link Building, Domestic Road, Domestic Airport, Pasay City 1301 Philippines UNDERGRADUATE STUDIES DEPARTMENT First Trimester, A.Y. 2024-2025 Aircraft Maintenance and Construction and Repair II (Composites) Tows and Rovings: Do not have any twists. Most fibers are available as dry fiber that needs to be impregnated with a resin before use or prepreg materials where the resin is already applied to the fiber. Roving A roving is a single set of filament or fiber ends, such glass rovings with 20 or 60 ends. There is no twisting and every filament is pointing in the same direction. Typically, carbon rovings are designated as 3K, 6K, or 12K rovings—K standing for 1,000 filaments. Unidirectional (Tape) For a long time, unidirectional prepreg tapes have been the norm in the aerospace sector. Thermosetting resins are usually used to impregnate fibers. The most popular manufacturing process involves pulling collimated raw, or dry, strands into an impregnation machine, which uses pressure and heat to mix the strands with hot, melted resins. Matrix Materials Thermosetting Resins Strengthen when heated and cannot be remolded or reheated after the initial forming. Examples include Polyester Resin, Vinyl Ester Resin, Phenolic Resin, Epoxy Resin, Polyimides, Polybenzimidazoles (PBI), and Bismaleimides (BMI). Thermoplastic Resins Can be reheated, remolded, and cooled as necessary without causing any chemical changes. Semicrystalline Thermoplastics: Possess inherent flame resistance, superior toughness, good mechanical properties, and low moisture absorption. Amorphous Thermoplastics: Known for their processing ease and speed, high- temperature capability, good mechanical properties, toughness, impact strength, and chemical stability. Polyether Ether Ketone (PEEK): A high-temperature thermoplastic with outstanding thermal and combustion characteristics. TYPES OF FIBERS  AIR LINK INTERNATIONAL AVIATION COLLEGE Air Link Building, Domestic Road, Domestic Airport, Pasay City 1301 Philippines UNDERGRADUATE STUDIES DEPARTMENT First Trimester, A.Y. 2024-2025 Aircraft Maintenance and Construction and Repair II (Composites) Types of Fibers Fiberglass Often used for secondary structures on aircraft, such as fairings, radomes, and wing tips. Electrical Glass (E-glass): Identified for electrical applications, made from borosilicate glass. S-glass and S2-glass: Structural fiberglass with higher strength than E-glass, produced from magnesia-alumina-silicate. Kevlar® DuPont’s name for aramid fibers is characterized by their yellow color. Kevlar® 49: High stiffness. Kevlar® 29: Low stiffness. Advantages include high resistance to impact damage, making them ideal for areas prone to such damage. Disadvantages include weakness in compression and hygroscopy, with some parts absorbing up to 8 percent of their weight in water. Carbon/Graphite Black graphite/carbon fiber is very strong, stiff, and used for primary structural components like ribs and floor beams. Advantages include high strength and corrosion resistance. Disadvantages include lower conductivity than aluminum, necessitating lightning protection for aircraft parts prone to lightning strikes, and high cost. Boron Very stiff with high tensile and compressive strength. Used primarily in military aviation applications, particularly for repairing cracked aluminum aircraft skins due to its thermal expansion properties, similar to aluminum. Ceramic Fibers Used for high-temperature applications, such as turbine blades in gas turbine engines, withstanding temperatures up to 2,200 °F. Goodluck and Stay Safe Everyone!