Composite Materials for Aircraft Structures, Second Edition

Contributors xix Introduction and Overview 1(22) General 1(2) Drivers for Improved Airframe Materials 3(1) High-Performance Fiber Composite Concepts 3(3) Fiber Reinforcements 6(1) Matrices 7(6) Polymer Matrix Composites 13(1) Non-polymeric Composite Systems 13(6) Hybrid Metal/PMC Composites 19(4) References 21(1) Bibliography 21(2) Basic Principles of Fiber Composite Materials 23(32) Introduction to Fiber Composite Systems 23(1) Micromechanical Versus Macromechanical View of Composites 23(2) Micromechanics 25(1) Elastic Constants 26(10) Micromechanics Approach to Strength 36(6) Simple Estimate of Compressive Strength 42(3) Off-axis Strength in Tension 45(2) Fracture Toughness of Unidirectional Composites 47(8) References 53(2) Fibers for Polymer-Matrix Composites 55(26) Overview 55(2) Glass Fibers 57(6) Carbon Fibers 63(4) Boron Fibers 67(2) Silicon Carbide 69(2) Aramid Fibers 71(2) Orientated Polyethylene Fibers 73(1) Dry Fiber Forms 74(7) References 79(2) Polymeric Matrix Materials 81(32) Introduction 81(5) Thermoset and Thermoplastic Polymer Matrix Materials 86(2) Thermosetting Resin Systems 88(20) Thermoplastic Systems 108(5) References 112(1) Component Form and Manufacture 113(58) Introduction 113(2) Outline of General Laminating Procedures 115(2) Laminating Procedures For Aircraft-Grade Composite Components 117(15) Liquid Resin Molding Techniques 132(8) Filament Winding 140(5) Pultrusion 145(4) Process Modelling 149(9) Tooling 158(4) Special Thermoplastic Techniques 162(9) References 169(2) Structural Analysis 171(42) Overview 171(1) Laminate Theory 172(19) Stress Concentration and Edge Effects 191(3) Failure Theories 194(9) Fracture Mechanics 203(1) Failure Prediction Near Stress Raisers and Damage Tolerance 204(3) Buckling 207(2) Summary 209(4) References 209(4) Mechanical Property Measurement 213(26) Introduction 213(3) Coupon Tests 216(9) Laboratory Simulation of Environmental Effects 225(2) Measurement of Residual Strength 227(4) Measurement of Interlaminar Fracture Energy 231(8) References 237(2) Properties of Composite Systems 239(50) Introduction 239(2) Glass-Fiber Composite Systems 241(6) Boron Fiber Composite Systems 247(2) Aramid Fiber Composite Systems 249(8) Carbon Fiber Systems 257(5) Properties of Laminates 262(1) Impact Damage Resistance 263(3) Fatigue of Composite Laminates 266(10) Environmental Effects 276(13) References 286(3) Joining of Composite Structures 289(80) Introduction 289(1) Comparison Between Mechanically Fastened and Adhesively Bonded Joints 290(2) Adhesively Bonded Joints 292(45) Mechanically Fastened Joints 337(32) References 366(3) Repair Technology 369(34) Introduction 369(1) Assessment of the Need to Repair 369(2) Classification of Types of Structure 371(1) Repair Requirements 371(3) Non-patch Repairs 374(3) Patch Repairs: General Considerations 377(2) Bonded Patch Repairs 379(11) Materials Engineering Aspects 390(4) Application Technology: In Situ Repairs 394(1) Bolted Repairs 395(3) Materials Engineering Aspects 398(5) References 401(2) Quality Assurance 403(32) Introduction 403(1) Quality Control 403(5) Cure Monitoring 408(6) Non-destructive Inspection of Advanced Composite Aerospace Structures 414(16) Conclusion 430(5) References 431(4) Aircraft Applications and Design Issues 435(42) Overview 435(1) Applications of Glass-Fiber Composites 435(1) Current Applications 436(11) Design Considerations 447(2) Design of Carbon-Fiber-Based Components 449(13) Design Methodologies 462(4) A Value Engineering Approach to the Use of Composite Materials 466(8) Conclusion 474(3) References 474(3) Airworthiness Considerations For Airframe Structures 477(14) Overview 477(3) Certification of Airframe Structures 480(2) The Development of Design Allowables 482(2) Demonstration of Static Strength 484(2) Demonstration of Fatigue Strength 486(1) Demonstration of Damage Tolerance 487(1) Assessment of the Impact Damage Threat 487(4) References 488(3) Three-Dimensionally Reinforced Preforms and Composites 491(34) Introduction 491(1) Stitching 492(6) Z-Pinning 498(4) Three-Dimensional Weaving 502(5) Braiding 507(8) Knitting 515(4) Non-crimp Fabrics 519(4) Conclusion 523(2) References 523(2) Smart Structures 525(24) Introduction 525(1) Engineering Approaches 526(5) Selected Applications and Demonstrators 531(13) Key Technology Needs 544(5) References 545(4) Knowledge-Based Engineering, Computer-Aided Design, and Finite Element Analysis 549(22) Knowledge-Based Design Systems 549(3) Finite Element Modelling of Composite Structures 552(1) Finite Element Solution Process 553(9) Element Types 562(1) Finite Element Modelling of Composite Structures 563(3) Implementation 566(2) Design Optimization 568(3) References 569(2) Appendix Overview of Some Sensors and Actuators Used for Smart Structure Applications 571(10) A.1 Piezoelectric Materials 571(2) A.2 Shape Memory Alloys 573(1) A.3 Optical Fiber Sensors 574(3) A.4 Electrorheological Fluids 577(1) A.5 Magnetostrictive Materials 577(1) A.6 Micro-Electro-Mechanical Systems 577(1) A.7 Comparison Of Actuators 578(3) References 579(2) Index 581(18) Supporting Materials 599