01 TCT-Stress Familiarization
01 TCT-Stress Familiarization
01 TCT-Stress Familiarization
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Composite Familiarization
For Training purposes only
Table of contents
1- Introduction 2- Fibre Material 3- Fibre Form 4- Matrix Material 5- Composite Form 6- Manufacturing Process 7- Assembly
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Page 2
1- Introduction
General Definition :A complex material, such as wood or fiberglass, in which two or more distinct, structurally complementary substances, especially metals, ceramics, glasses, and polymers, combine to produce structural or
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Today, when we speak of composite materials, or just "composites", we are referring to the highly engineered combinations of polymer resins and reinforcing materials such as glass/carbon fibers.
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1- Introduction
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Page 4
1- Introduction
Composites on A380
GLARE in Upper Fuselage CFRP Ailerons CFRP Vertical Tail Plane CFRP Spoilers CFRP Floor Beams for Upper Deck
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CFRP Section 19
1- Introduction
CFRP on A400M
Centre Wing Box Fairings
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1- Introduction
2500
Metals Vs Composites
Higher Strength Higher Stiffness No plasticity Lower strain levels Lower fracture energy
N/mm2
IM Carbon UD Tape
Fibre Characteristics
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1500
Stress
1000
HS Carbon fabric
Aluminium 7075-T6
Resin Characteristics
Lower strength
Lower Stiffness
Strain
0.005
0.01
0.015
0.02
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1- Introduction
Composites Vs Metals
Structural Issues
Interlaminar/Through thickness failures
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S
Through Thickness
F
Interlaminar shear
+
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1- Introduction
Composites Vs Metals
Structural Issues
Environmental effects (Heat / Moisture reduce Material Properties)
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Page 9
1- Introduction
Composites Vs Metals
Structural Issues
Environmental effects (Heat / Moisture reduce Material Properties)
-1- Hole effect in tension after wet ageing -2- Hole effect in compression after wet ageing
1.4 1.2 1
0.8
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1.2
0.8
0.6
0.6
0.4
0.4
0.2
0.2 0
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1- Introduction
Composites Vs Metals
Structural Issues
Impact (Barely Visible Impact Damage - BVID)
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1- Introduction
Composites Vs Metals
Structural Issues
Notch Sensitivity different to metallics
METALLICS
COMPOSITES
Stress peak behaviour different to metallics
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1- Introduction
GENERIC METHODS
Composites Vs Metals
Manufacturing
Methods
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Composite
Lay -up to shape Bolt/Bond Inspect
Metal
Machine Bolt Resin Rich Area
Defects (e.g Resin rich areas, inclusions, voids, incorrect ply lay-ups etc) Tolerances > metals (Thickness Variations, springback, warpage)
Cover
Cost
Material ~ 80-100% > metals Assembly/Machining ~ 10 -15% > metals In service (maintenance etc) ~ 30% < metals
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1- Introduction
What are the options? What are the most important characteristics?
What is the Airbus initial choice and what are the important issues to take into account during decision making?
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Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies
Fibre Form
NCF Woven pre- form Uni directional Chopped strand
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Glass
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Low Density = 2.6g/cm3, Moderate stiffness ~60% CF, Good strength ~60-80% CF,
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and price
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High/Very High Stiffness (cf Glass) High/Very High Strength (cf Glass) Very Low Density = 1.6g/cm3
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Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies
Fibre Form
NCF Woven pre- form Uni directional Chopped strand
Pre-Preg.Pre impregnated NCF Non crimped fabric RTM Resin Transfer moulding RFI.. Resin Film infusion
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Woven
Composite Stress - Familiarization - For Training purposes only-
Characteristics
2 1
High strength & stiffness (1-1) High compression stability Low drape capability Un-crimped fibres
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ve ea
2
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Page 22
Characteristics
High cost (raw material) High deposition rate High tension strength/stiffness (1-1) Lower compression stability Slightly crimped fibres Good drape? Variability?
2 1
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Important Issues
Thickness Impact Resistance Drapeability Strength & Stiffness Manufacturing/Material costs
Composite Stress - Familiarization - For Training purposes only-
Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies
Fibre Form
NCF Woven pre- form Uni directional Chopped strand
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High temp, expensive, difficult to process (matrix microcracking) Expensive, electrically transparent, low moisture absorb Very high temp, expensive Lower properties than epoxies
Good resistance to chemical attack Adequate high temp properties Good secondary bond strength Can be formulated to meet a wide range of processing
Epoxies
Available as Room temp epoxies (eg Araldite) Elevated temperature curing (pre preg)
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Tg ~ Glass transition temperature, determines max operating temperature of material (from 100 to 150 degrees) depending on environment
2 Module G (N/mm )
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0.40
Tg
103 2 WET 2 5.102 1 1 DRY
0.30
0.20
0.10
40
60
X X 80 100 120 140 160 180 200 220 240 260 280 300 320 340 95C 120C Temperature (C)
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Tensile Strength 60-80 MPa Tensile Modulus 3000-4000 MPa Performance decrease by moisture pick-up and T Brittle Resistant to aggressive media (Skydrol, de-icing etc) Sensitive to UV => top coat required
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Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies
Fibre Form
NCF Woven pre- form Uni directional Chopped strand
Pre-Preg.Pre impregnated NCF Non crimped fabric RTM Resin Transfer moulding RFI.. Resin Film infusion
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Matrix
Mechanical: High stiffness Low stiffness Thermal: Small (-ve ) Larger (+ve) Moisture: No change Swelling & shrinkage Terminology Fibre Weight Fraction Fibre Volume Fraction Porosity
Note: Nomenclature
Vp < 1-2% required for a/c structural application Vf altered during manufacturing by bleeding resin (improves Mechanical properties)
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E1
50 40
GN/m2
Ef-Em
30
20 10
E.g. GF/PE
Em
0.1 0.2 0.3 0.4 0.5 0.6 0.7
c = f vf + m vm
Composite Stress - Familiarization - For Training purposes only-
Vf
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Lamina has material Axes 1 2 3 Laminate has axes x y z Orientate and define 1 2 3 with respect to x y z
3 2 1
Analysis Approaches
Individual fibre and matrix response Apparent homogeneous/orthotropic response (Average individual fibre/matrix response in laminate directions)
z z y x x y
2 1 1 2
1 2
y x
Individual Response
Nomenclature
P0 ~ % 0o fibres / 100 P45 ~ % 45o fibres / 100 P90 ~ % 90o fibres / 100
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4 plies max adjacent same orientation (depending on thickness) 45 degree angle change + - 45 on surface Balanced Symmetric
Tailoring as Required
0o DIRECTION PLIES IN SKIN TO REACT BENDING / DIRECT LOAD 45o / 135o DIRECTION IN SKIN TO REACT SHEAR 90o DIRECTION TO REACT BOLT BEARING, FUEL PRESSURE AND AERODYNAMIC SUCTION.
Composite Stress - Familiarization - For Training purposes onlyPage 36
Joint Guidelines
P L Y ID T H
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AG
AG
AG
GE
IN
DE
T IO
ST
ST
S T A R
1 5 ( N o m m m ')
P O
I N
ST
Skin: 1:20 Spanwise 1:10 Chordwise Spar: as skin but may go up to 1:5 Rib: 1:20 but may go up to 1:5
NA
NA
Arrow
Composite Stress - Familiarization - For Training purposes only-
Diamond
Page 37
Fibre orientation Roll Orientation Line No (Parts List) Material Stagger Index
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5- Composite Form
Composite Form - AIRBUS most common choice Lamina: UD Epoxy pre preg Lay-up: Tailored to suit load direction
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Cost (Sandwich, Lamina) Moisture Ingress (Sandwich) Availability (Sandwich, Lamina) Is it approved ? (Sandwich, Lamina) Definition of axes relative to laminate plate (Lay-up) Follow Lay-up/Stacking/Terminology rules (Lay-up/Stacking)
Composite Stress - Familiarization - For Training purposes onlyPage 41
Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies
Fibre Form
NCF Woven pre- form Uni directional Chopped strand
Pre-Preg.Pre impregnated NCF Non crimped fabric RTM Resin Transfer moulding RFI.. Resin Film infusion
Page 42
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Manufactured Component
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Forming
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Curing (Autoclave)
Characteristics
Material cost high Fair quality and accuracy
Second set of rollers establishing blade Final roll controlling finished profile
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Characteristics
Fair quality Low Material Cost Time efficient
Composite Stress - Familiarization - For Training purposes onlyPage 45
Hand Lay-up onto forming tool (multi-surface) Hot de-bulk creating pre-form Transfer to cure tool
Characteristics
High tooling cost (High Volume Process) Low Material Cost Very good Tolerance on all faces
Composite Stress - Familiarization - For Training purposes onlyPage 46
Hand Lay-up onto forming tool (single surface) Hot de-bulk creating pre-form Transfer to cure tool
Characteristics
Lowest quality Lowest cost
Composite Stress - Familiarization - For Training purposes onlyPage 47
Component scale and complexity Manufacturing process technology Balance between cost, accuracy, thermal mass
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Options
Steel - high accuracy for small part
Aluminum - high CTE, low cost Invar - highest accuracy, cost and durability Composite - lower thermal mass, shorter life
breather blanket caul plate vacuum bag release film
component
Rubber mandrels
Solid mandrels
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6- Manufacturing Process
Manufacturing Process: AIRBUS most common choice
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Important issues:
Strength/Stiffness properties (material)
Increase Vf of material (process) ?
Cost (material/process/tooling) Accuracy/Tolerance/Quality (process/tooling) Temperature (Tg of resin) Thermal Mass (Tooling) Non Recurring Costs (Autoclave/Facilities etc)
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Matrix Material
Thermoplastics Thermosets
Polyester Phenolics Bismalemides Cyanate Esters Polyimide Epoxies
Fibre Form
NCF Woven pre- form Uni directional Chopped strand
Pre-Preg.Pre impregnated NCF Non crimped fabric RTM Resin Transfer moulding RFI.. Resin Film infusion
Page 51
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Bolted Joints
Galvanic corrosion (Titanium Bolt/Glass) Thermal coefficient mismatch Failure issues around holes Sealing Failure mode sensitive to out of plane loading
Bonded Joints
Surface preparation Operating Temperature Failure issues at bond joint Lightening strike consideration Highly sensitive to out of plane loading
Composite Stress - Familiarization - For Training purposes only-
G. Peel/Disbond
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5d
2.5d
4d-6d typ
4 Fasteners 5 Fasteners
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CO CURE
Component 1 un-cured Component 2 un-cured Cured together effectively creating a single part
1
Adhesive
CO BOND
2
Component 1 cured Component 2 un-cured Bonded together during cure of cure cycle of component 2
1
Adhesive
SECONDARY BOND
2
Component 1 cured Component 2 cured Bonded together with separate bonding operation
Liquid shim : between 0.4mm and 0.7mm upper limit (harmonization ongoingdepends on design) Solid Shim > 0.5mm (validated by tests :static, fatigue)
Carbon dust extraction essential during drilling procedure In-jig access to be considered for additional jig features
Shimming tooling
Bonding tooling
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Important issues:
Strength/Stiffness (Joints)
Weight (Joints) Cost (Joints/Jig/Shimming) Repair/Inspection (Joints) Tolerance (Jig/Shimming) Thermal Mass (Jig) Health and Safety (Joints/Jig) Access (Jig)
Composite Stress - Familiarization - For Training purposes onlyPage 56
Manufacturing Process: Pre-preg ATL Joints: Bolted (Bonded if co-cured) Shim: aim for no shim, liquid then solid/liquid if needed Important issues:
Strength/Stiffness
AUTHORS
Function NatCos
A-F
AIRBUS S.A.S. 2006. All rights reserved. Confidential and proprietary document.
Name
Mike Stephens
APPROVAL
Domain
Head of ESAC
Name
Chantal Fualdes
Signature
Signed electronically 27/06/2006
Page 58
Record of Revisions
RECORD OF REVISIONS
Issue
1 2 3 4
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Date
For general queries or information contact: Airbus Documentation Office Airbus SAS 31707 Blagnac CEDEX France Tel: +33 [0] 561 93 49 93 Fax: +33 [0] 561 93 27 44
Composite Stress - Familiarization - For Training purposes onlyPage 59
AIRBUS S.A.S. 2006. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS S.A.S.. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied.
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The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.
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