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Advanced Composite materials. Used in construction on new technology aircraft and considerations in their use P éter Marosszéky FRAeS MIFA MAOPA (USA) Adjunct Senior Lecturer & Research Fellow University of New South Wales School of Aviation Faculty of Science. Introduction. - PowerPoint PPT Presentation
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22/04/2023 New Technology composites 1
ADVANCED COMPOSITE MATERIALS
Used in construction on new technology aircraft and considerations in their use
Péter Marosszéky FRAeS MIFA MAOPA (USA)Adjunct Senior Lecturer & Research Fellow
University of New South Wales School of AviationFaculty of Science
IntroductionThe areas that need to be
considered:• Occupational Health and Safety• Advanced composites • Damage tolerance and assessment• Repair Assessments• Repair schemes & processes• Specialized equipment & tooling• Approved MRO’s• Training
Health & Safety Hazards• Risks & hazards can be controlled• Use of MSDS data• A wide range of safety procedures
have been developed and approved• Current FAR 145.163 and EASA
Advisory Circular 65-33 requirements
• High overheads & retraining • Manufacturer programs ie:
Boeing’s “Gold Care” program
Advanced CompositesA range of advanced composites in use
on new generation aircraft• Two primary advanced composites are in
use on the Boeing 787 and the Airbus A350XB
• Boeing have opted for the Torayca 3900-series highly toughened carbon fibre-
reinforced epoxy prepreg – unidirectional tape (various widths) & narrow slit tape (for fibre replacement) and woven fabric forms Majority of the 3900 – series made from intermediate modulus T800S fibre.
Advanced Composites • Boeing continued: • The surface finishing provides
resistance against moisture and contaminant ingress: Cytec SurfaceMaster 905.
• A high-temperature bisaleimide composite material, that allows application & removal of paint without compromising the integrity of the sub-structure
Boeing 787 series
Boeing 787 continued• Other primary structures• Window frames & Engine Nacelles
use Hexcel HexMC trademarked as HexPly AS4 carbon fibre prepreg (350°C/177°F cure) 8552 epoxy prepreg resin (Nordam)
• Wing & Trailing edge components use Hexcel’s HexFlow RTM6 with Cytec Surface Master 905
• Some landing gear components utilize Hexcel IM-7 fibre.
Airbus A380 series • Primary structure:• Empennage – Carbon fibre reinforced
plastic (CFRP)• Fin leading edge – Glass fibre reinforced
plastic (GFRP)• Radome – Quartz fibre reinforced plastic
(QRFP)• Upper sections of fuselage – Glass
reinforced Aluminium Laminate (GLARE)
Airbus A380 series
Airbus A350XB series Airbus have selected the Hexcel
HEXPLY M-21E Carbon fibre toughened epoxy prepreg composite for primary
structures
Damage tolerance & assessment
• Advanced composites have Significant weight, stiffness and strength advantages over Aluminium
• Advanced composites are susceptible to damage with greater resistance than
Aluminium • Advanced composites are susceptible to
sunlight (infra-red) exposure, however pre-spun prepreg carbon fibre is less
affected due to the tight weave reducing surface area of resins/catalysts
Damage tolerance & assessment continued…• Boeing and Airbus tests have been
validated by the ASTMAdvanced Carbon fibre in use on the 787 and A350 has been certified to
allow continued airworthiness if impact contact does not leave a visible sign, no further action need be takenIf damage is visible then action must
be taken in accordance with the respective SRM (Structural Repair
Manual)
Damage tolerance & assessment continued…An example of the effects of damage and subsequent fatigue propagation, tests have shown that in tight weave carbon fibre a breach of the structure not exceeding 2.54cm/1.0in. Will not
propagate any furtherLarger areas of damage repaired and
processed in accordance with manufacturer specifications will have
permanent repair status.
Damage tolerance & assessment continued…
Airbus research and assessment (validated by (ASTM) has shown the
damage tolerance of GLARE is significantly better than Aluminium,
however not as resistant Carbon fibre prepreg
Damage tolerance & assessment continued
• Electrical and Fluid exposure damage.
• Electrical:• Advanced Carbon composites are
electrical conductors • Copper mesh is embedded in the
structure to provide for conductivity and earth return for electrical systems as the “earth return”
Damage tolerance & assessment continued…
• Fluid exposure:• Coatings applied during
manufacture provide protection against phosphate ester fluid (Hydraulic fluids) ingress
• Water and waste protection against ingress
• Corrosion is prevented by the use of Titanium fasteners
General & specific applications
Repair assessments• Considerations of damage
assessment• Area of damage• Location• Structural requirements• Type of material• Equipment and materials
available at location
Repair assessments continued…
• Repair must be in accordance with manufacturers SRM
• Must consider:• Proximity to major structural
elements• Aerodynamic cleanliness
especially for RVSM and RNP factors
• Repair permanency
Inspection products• Portable FTIR4100 Fourier Transform Infra-
Red (FTIR) spectroscopy to measure the effect of heat damage caused by lightning
strikes, fire and engine exhaust• Olympus NDT35RDC hand held device check
for possible impact damage include sub-surface damage
• BondMaster1000e multi-mode test device to check for disbonding & delaminations.
• OmniScan MX and Epoch 1000i using two similar ultrasonic phased array device to
detect cracks, delaminations and inclusions
Repair Schemes & processes
• Most repairs envisaged for in-service will be conducted in-situ, manufacturers have
designed specific repair schemes for the range of materials & structures
• MRO’s are developing processes for repair & maintenance of advanced composites eg;
Lufthansa Technik AG has developed a method for the semi-automated repair of fibre
composites, process uses scanning to within 1/100th of a millimetre using optical
measurement techniques & computer controlled milling machine to create the
bonded surface & perfectly matched pre-cuts of individual composite layers.
Specialized equipment & tooling
• Some of these include:• The HEATCON HCS9200B Dual zone
hot bonder• The HEATCON HCS9000B Single zone
hot bonder• The HEATCON HCS2046-02 Phosphoric
Acid Containment System (PACS) • A range of Composite Cutting Tools
(CCT) for accurate and damage free machining & shaping
Approved organizations
• Currently most MRO’s and airline MRO’s are gearing up for regulator
& manufacturer accreditation• OEM’s also provide after market
services for operators that do not have access to approved
organizations.
TrainingThere are a number of training
organizations that provide Advanced Composite training in addition to
OEM’s. This type of training is referred to as Advanced Skills training,
requiring on-going refresher training to retain qualifications and proficiency.A Part 145 organization must receive
training from a Part 147 training organization.
Questions
Thank you