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Composite is a broad term and can mean materials such as fiberglass, carbon fiber cloth, Kevlar© cloth, and mixtures of all of the above. Composite construction offers two advantages: extremely smooth skins and the ability to easily form complex curved or streamlined structures. [Figure 2-15]
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Figure 2-15. Composite aircraft.
Advantages of Composites
Composite construction offers several advantages over metal, wood, or fabric, with its lighter weight being the most frequently cited. Lighter weight is not always automatic. It must be remembered that building an aircraft structure out of composites does not guarantee it will be lighter, it depends on the structure, as well as the type of composite being used.
A more important advantage is that a very smooth, compound curved, aerodynamic structure made from composites reduces drag. This is the main reason sailplane designers switched from metal and wood to composites in the 1960s. In aircraft, the use of composites reduces drag for the Cirrus and Columbia line of production aircraft, leading to their high performance despite their fixed landing gear. Composites also help mask the radar signature of “stealth” aircraft designs, such as the B-2 and the F-22. Today, composites can be found in aircraft as varied as gliders to most new helicopters.
Lack of corrosion is a third advantage of composites. Boeing is designing the 787, with its all-composite fuselage, to have both a higher pressure differential and higher humidity in the cabin than previous airliners. Engineers are no longer as concerned about corrosion from moisture condensation on the hidden areas of the fuselage skins, such as behind insulation blankets. This should lead to lower long-term maintenance costs for the airlines.
Another advantage of composites is their good performance in a flexing environment, such as in helicopter rotor blades. Composites do not suffer from metal fatigue and crack growth as do metals. While it takes careful engineering, composite rotor blades can have considerably higher design lives than metal blades, and most new large helicopter designs have all composite blades, and in many cases, composite rotor hubs.
Disadvantages of Composites
Composite construction comes with its own set of disadvantages, the most important of which is the lack of visual proof of damage. Composites respond differently from other structural materials to impact, and there is often no obvious sign of damage. For example, if a car backs into an aluminum fuselage, it might dent the fuselage. If the fuselage is not dented, there is no damage. If the fuselage is dented, the damage is visible and repairs are made.
In a composite structure, a low energy impact, such as a bump or a tool drop, may not leave any visible sign of the impact on the surface. Underneath the impact site there may be extensive delaminations, spreading in a cone-shaped area from the impact location. The damage on the backside of the structure can be significant and extensive, but it may be hidden from view. Anytime one has reason to think there
Composite Materials in Aircraft
Composite materials are fiber-reinforced matrix systems. The matrix is the “glue” used to hold the fibers together and, when cured, gives the part its shape, but the fibers carry most of the load. There are many different types of fibers and matrix systems.
In aircraft, the most common matrix is epoxy resin, which is a type of thermosetting plastic. Compared to other choices such as polyester resin, epoxy is stronger and has good high-temperature properties. There are many different types of epoxies available, with a wide range of structural properties, cure times and temperatures, and costs.
The most common reinforcing fibers used in aircraft construction are fiberglass and carbon fiber. Fiberglass has good tensile and compressive strength, good impact resistance, is easy to work with, and is relatively inexpensive and readily available. Its main disadvantage is that it is relatively heavy, and it is difficult to make a fiberglass load-carrying structure lighter than a well designed equivalent aluminum structure.
Carbon fiber is generally stronger in tensile and compressive strength than fiberglass, and has much higher bending stiffness. It is also considerably lighter than fiberglass. However, it is relatively poor in impact resistance; the fibers are brittle and tend to shatter under sharp impact. This can be greatly improved with a “toughened” epoxy resin system, as used in the Boeing 787 horizontal and vertical stabilizers. Carbon fiber is more expensive than fiberglass, but the price has dropped due to innovations driven by the B-2 program in the 1980s, and Boeing 777 work in the 1990s. Very well-designed carbon fiber structures can be significantly lighter than an equivalent aluminum structure, sometimes by 30 percent or so.
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Figure 2-16. Impact energy affects the visibility, as well as the severity, of damage in composite structures. High and medium energy impacts, while severe, are easy to detect. Low energy impacts can easily cause hidden damage.
　
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