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    Aircraft Materials, Construction and Repair

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    Mark Jovince Cardenas
    This document discusses aircraft plastics, including their uses in aircraft applications and classifications. The two main types are thermoplastics, which can be reshaped after heating and cooling, and thermosetting plastics, which permanently harden after heating. Common manufacturing processes for plastics include molding, casting, extruding, and laminating. The document also covers joining, machining, and forming of plastic aircraft parts.

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    Aircraft Materials, Construction and Repair

    Uploaded by

    Mark Jovince Cardenas
    50 views20 pages
    This document discusses aircraft plastics, including their uses in aircraft applications and classifications. The two main types are thermoplastics, which can be reshaped after heating and cooling, and thermosetting plastics, which permanently harden after heating. Common manufacturing processes for plastics include molding, casting, extruding, and laminating. The document also covers joining, machining, and forming of plastic aircraft parts.

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    This document discusses aircraft plastics, including their uses in aircraft applications and classifications. The two main types are thermoplastics, which can be reshaped after heating and cooling, and thermosetting plastics, which permanently harden after heating. Common manufacturing processes for plastics include molding, casting, extruding, and laminating. The document also covers joining, machining, and forming of plastic aircraft parts.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    50 views20 pages

    Aircraft Materials, Construction and Repair

    Uploaded by

    Mark Jovince Cardenas
    This document discusses aircraft plastics, including their uses in aircraft applications and classifications. The two main types are thermoplastics, which can be reshaped after heating and cooling, and thermosetting plastics, which permanently harden after heating. Common manufacturing processes for plastics include molding, casting, extruding, and laminating. The document also covers joining, machining, and forming of plastic aircraft parts.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 20

    Aircraft Materials,

    Construction and Repair


    Aircraft Plastics
    Aircraft Plastics

     Plastics are a large group of synthetic and natural organic


    materials which can be molded under heat and pressure,
    cast, extruded, or fabricated into a variety of shapes.
     Plastics have been used in many aircraft applications and
    recent developments indicate a broadening of such
    applications.
     In addition they have been used in the manufacture of
    fairings, emergency hatch covers, control-surface tabs, wing
    tips, droppable fuel tanks, wheel fairings, air ducts,
    windows, windshields, interior furnishings etc.
    Wheel Fairings

    Flap Track Fairings


    Major Classifications of Plastic

     Thermoplastics
     Thermosetting Plastics
    Thermoplastics

     Thermoplastic materials will repeatedly soften when


    heated and harden when cooled. These materials. can be
    heated until soft, molded into the desired shape, and
    when cooled will retain this shape.
    Thermoplastics

     Two types of transparent thermoplastic materials are used


    for aircraft windshields and side windows.
     Cellulose acetate and Acrylic.
    Thermoplastics

     Cellulose Acetate
     Early aircraft used cellulose acetate plastic because of its
    transparency and light weight. However, it has a tendency to
    shrink and turn yellow and, therefore, has almost completely
    been replaced.
     Cellulose acetate can be identified by its slightly yellow tint
    and the fact that, if a scrap of it is burned, it produces a
    sputtering flame and dark smoke.
     Another way to identify cellulose acetate is with an acetone
    test. When acetone is applied to cellulose acetate it softens.
    Thermoplastics

     Acrylic plastics are identified by such trade names as


    Lucite or Plexiglas.
     Acrylic is stiffer than cellulose acetate, more transparent
    and, for all practical purposes, is colorless. It burns with a
    clear flame and produces a fairly pleasant odor.
    Furthermore, if acetone is applied to acrylic it leaves a
    white residue but remains hard.
    Thermosetting Plastics

     Thermosetting plastics are chemically changed by the first


    application of heat and are thereafter infusible. They will
    not soften on further application of heat and cannot be
    reshaped after once being fully cured by the application
    of heat.
    Manufacturing Process

     A number of manufacturing processes are employed to


    create usable forms of plastics for industrial applications.
    Some of these processes are applicable only to
    thermosetting materials or thermoplastic materials while
    others are used for· either type of plastic.
    Molding

     Both thermoplastic and thermosetting materials can be


    molded satisfactorily. The molding compound usually
    consists of the plastic resin and a filler, and sometimes a
    plasticizer which improves the molding properties.
    Compression Molding

     This process is equivalent to the press forging


    of metals. It consists of placing molding
    compound in a heated mold cavity, and then
    applying pressure to the other half of the
    mold.
     This process is used with thermoplastic
    materials the mold must be aftercooled to
    harden the plastic part before. it is ejected.
    Molding pressures of from 1000 to 20,000 psi.
    and temperatures around 300°F. are used in
    this process.
    Injection Molding

     Parts manufactured by this process


    have good dimensional accuracy. In
    this process the molding compound
    is heated in a chamber from which it
    is forced by a ram into a relatively
    cool mold.
     It is applicable to thermoplastic
    parts of relatively simple design not
    weighing over 2 pounds.
    Casting

     This process is usually limited to thermosetting materials


    which are poured into molds and hardened by slow baking.
    Extruding

     This process is applicable to thermoplastic materials. It is


    used to produce rods, tubes, strips, and other sections as
    well as to insulate wire and cable.
     In this process the molding compound is softened by
    heating, and is then forced through a die with an aperture
    of the desired shape. Continuous extruding is obtained by
    using a self-feeding screw-type ram or stuffer.
    Laminating

     This process is applicable to thermosetting plastic materials.


    These laminates consist essentially of a reinforcing material
    such as paper, fabric, or glass fiber, impregnated with a
    synthetic-resin binder, layers of which are fused together
    under heat and pressure.
     To manufacture laminated sheet a number of the impregnated
    sheets are piled on top of each other and placed in a hydraulic
    press. They are then subjected to a temperature and 300°F
    and a pressure of from 1000 to 2500 psi. During this curing
    operation the resin is transformed into an infusible solid, after
    which the laminate is removed from the press.
    Joining

     Plastic materials are usually joined by means of rivets,


    bolts, screws, or inserts. When using rivets or bolts it is
    advisable to use washers under the heads to distribute the
    compressive load of the riveting or nut tightening.
     In joining laminated-plastic materials it is important that
    the fastenings apply the loads across the laminations.
    Machining

     Plastics can be machined without difficulty but the


    reinforced thermosetting plastics are very hard on cutting
    tools, causing them to dull rapidly. In general, tools with
    cemented tungsten carbide or satellite tips are used.
     Overheating caused by excessively high speed or a dull
    tool will result in a poor finish and inaccurate dimensions.
    Forming

     Thermosetting plastics have very little ductility at room


    temperatures and cannot be formed like metals. Single-
    curvature parts with a large radius can be formed but
    must be held in this shape by adequate fastening.
     It is difficult to mold the high-pressure laminates in any
    but flat or simple curved shapes; but low pressure
    laminates can be molded to practically any desired shape.

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