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Composite Materials for Aircraft Structures Second Edition PDF

602 Pages·2008·10.02 MB·English
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Composite Materials for Aircraft Structures Second Edition Alan Baker Cooperative Research Centre for Advanced Composite Structures, and Defence Science and Technology Organisation, Department of Defenee, Australia Stuart Dutton Cooperative Research Centre for Advanced Composite Structures Donald Kelly University of New South Wales IId A! A A~ EDUCATION SERIES Joseph A. Schetz Series Editor-in-Chief Virginia Polytechnic Institute and State University Blacksburg, Virginia Published by American Institute of Aeronautics and Astronautics, Inc. 1801 Alexander Bell Drive, Reston, VA 20191-4344 American Institute of Aeronautics and Astronautics, Inc., Reston, Virginia 2 3 4 5 Baker, A. A. (Alan A.) Composite materials for aircraft structures / Alan Baker, Stuart Dutton, and Donald Kelly-- 2nd ed. p. cm. -- (Education series) Rev. ed. of: Composite materials for aircraft structures / edited by B. C. Hoskin and A. A. Baker. ISBN 1-56347-540-5 .1 Airplanes-Materials. 2. Compsite materials. I. Durron, Stuart. II. Kelly, Donald, Donald (Donald W.) III. Title. IV. Series: AIAA education series. TL699.C57B35 2004 629.134--dc22 200401219 Copyright © 2004 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved. Printed in the United States. No part of this publication may be reproduced, distributed, or transmitted, in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the publisher. Data and information appearing in this book are for informational purposes only. AIAA is not responsible for any injury or damage resulting from use or reliance, nor does AIAA warrant that use or reliance will be free from privately owned rights. AIAA Education Series Editor-in-Chief Joseph A. Schetz Virginia Polytechnic Institute and State University Editorial Board Takahira Aoki David K. Holger University of Tokyo lowa State University Robert H. Bishop Rakesh K. Kapania University of Texas at Austin Virginia Polytechnic Institute and State University Claudio Bruno University of Rome Brian Landrum University of Alabama, Aaron R. Byerley Huntsville .S.U Air Force Academy Achille Messac Richard Colgren Rensselaer Polytechnic Institute University of Kansas Michael Mohaghegh Kajal K. Gupta The Boeing Company NASA Dryden Flight Research Center Todd .J Mosher University of Utah Albert Helfrick Embry-Riddle Aeronautical Conrad F. Newberry University Naval Postgraduate School Rikard B. Heslehurst David K. Schmidt Australian Defence Force University of ,odaraloC Academy Colarado Springs David M. Van Wie Johns Hopkins University Foreword This Second Edition of Composite Materials for Aircraft Structures edited by Alan Baker, Stuart Dutton and Donald Kelly is an updated, comprehensive treatment of a stimulating and challenging subject in the aerospace field with ever increasing importance. The First Edition has proven to be a valuable part of the AIAA Education Book Series, and we are delighted to welcome this new edition to the series. The lead editor of the First Edition, Brian Hoskin, has since passed away, but the new editorial team has done an admirable job of maintaining the high standards of the earlier book. The Second Edition features considerable new and updated material, and there are now 16 chapters and an appendix. The evolution of this edition is traced in the Preface. The AIAA Education Series aims to cover a very broad range of topics in the general aerospace field, including basic theory, applications and design. A complete list of titles published in the series can be found on the last pages in this volume. The philosophy of the series is to develop textbooks that can be used in a college or university setting, instructional materials for intensive continuing education and professional development courses, and also books that can serve as the basis for independent self study for working professionals in the aerospace field. We are constantly striving to expand and upgrade the scope and content of the series, so suggestions for new topics and authors are always welcome. JOSEPH A, SCHETZ Editor-in-Chief AIAA Education Series vii Foreword to first edition etisopmoC Materials for Aircraft Structures, edited by B. C. Hoskin and A. A. Baker, is the latest addition to the AIAA Education Series inaugurated in 1984. The series represents AIAA's response to the need for textbooks and monographs in highly specialized disciplines of aeronautics and astronautics. Composite Materials for Aircraft Structures, just such a case in point, should prove particularly timely because the field has surged in composite applications. etisopmoC Materials for Aircraft Structures provides a broad introduction to virtually all aspects of the technology of composite materials for aircraft structural applications: the basic theory of fiber reinforcements; material characteristics of the commonly used fibers, resins, and composite systems; components form and manufacture; structural mechanics of composite laminates; composite joints; environmental effects; durability and damage tolerance; nondestructive inspection (NDI) and repair procedures; aircraft applications; and airworthiness considerations. This text, expanded and updated, has been prepared from notes used in a series of lectures given at the Aeronautical Research Laboratories (ARL), Melbourne, Victoria, Australia. All lecturers were officers in either the Structures or Aircraft Materials Divisions of ARL. The table of contents gives the names of the lecturers, together with their topics. The lectures originated with a request to ARL from the Australian Department of Aviation' s Airworthiness Branch. The Director of the Aeronautical Research Laboratories, Department of Defense, Australia, has authorized publication of the expanded and updated text by AIAA. J. S. PRZEMIENIECKI Editor-in-Chief AIAA Education Series ix Preface This book is a revised and extended edition to the original 1986 book etisopmoC slairetaM for Aircraft ,serutcurtS edited by Brian Hoskin and Alan Baker of the then Aeronautical Research Laboratories in Melbourne, Australia. In 1997, staff responsible for the AIAA Education Series invited Brian and Alan to produce a sequel, but sadly Brian had passed away some years ago. However, Alan was still working full-time as Research Leader of Aerospace Composite Structures at the Australian Defence Science and Technology Organisation (DSTO) and actively engaged in the research activities of the Cooperative Research Center for Advanced Composite Structures Limited (CRC-ACS), which had been established in 1991. This was fortuitous, as Alan was able to call upon the support of a relatively large team of experts working in the CRC-ACS and its member organizations, to undertake the requested revision. The work on the revised edition began in 1998, as a CRC-ACS education program task led by Alan and supported by the then Director, Dr Gordon Long. The task progressed slowly as most of the contributors were heavily committed, however it continued to be supported by the new CRC-ACS Chief Executive Officer (CEO), Dr Ian Mair. In order to assist Alan in what seemed to be an ever- increasing task, two co-editors joined him: Mr Stuart Dutton, Deputy CEO of the CRC-ACS, and Prof. Don Kelly, Professor at the University of New South Wales. Stuart and Don are widely respected in the Australian composites research community for their contributions to the advancement of the design and manufacture of advanced composite structures. Whilst much has changed in composites technology since the original book was written, some topics (at the level required) have not changed that much, so they are incorporated into this book more or less unchanged. In particular, the material in the chapter on Structural Analysis by Brian Hoskin has been retained, essentially unchanged. Also, the chapter on Basic Principles, although renamed, is much the same as in the original edition. The remainder of the book is significantly different from the original, except that some of the figures have been recycled. There are now 16 chapters and an appendix, which together provide an outstanding overview and, in many areas, a very detailed expos6 of the most important aspects of composite materials for aircraft structures. Whilst this book has been produced with the support of the CRC-ACS, the efforts of each of the contributors from the CRC-ACS and its members, such as DSTO and Hawker de Havilland, are gratefully acknowledged. Finally, I wish to iix ECAFERP congratulate the three co-editors for their commitment to this task over the last few years and their success in completing this valuable text book. MURRAY L. SCOTT Chief Executive Officer Cooperative Research Centre for Advanced Composite Structures Melbourne, Australia Contributors retpahC Contributors 1. Introduction and Overview A. A. Baker* 2. Basic Principles of Fiber Composite A. A. Baker Materials A. Rachinger* 3. Fibers for Polymer-Matrix Composites A. A. Baker K. H. Leong* 4. Polymeric Matrix Materials A. A. Baker J. Hodgkin ¢ M. Hou* 5. Component Form and Manufacture A. A. Baker R. Paton* T. Kruckenburg* P. Falzon* I. Crouch* S. Dutton* M. Hou* X. Liu* W. Hillier* 6. Structural Analysis B. Hoskin* D. Kelly ~ R. Li § 7. Mechanical Property Measurement M. Bannister* A. A. Baker A. Garg ¶ A. A. Kharibi** Y. W. Mai** snoitailiffA at eht time of :gnitfard ,OTSD* Dept of ,ecnefeD htlaewnommoC of ailartsuA SCA-CRC* .dtL tnemtrapeD* of raluceloM ,ecneicS ORISC ytisrevinU~ of weN htuoS selaW rekwaH~ eD dnallivaH ecapsoreA .dtL ytisrevinU** of yendyS xx CONTRIBUTORS 8. Properties of Composite Systems A. A. Baker A. Mouritzt* R. Chester* M. Bannister 9. Joining of Composite Structures A. A. Baker D. Kelly .01 Repair Technology A. A. Baker .11 Quality Assurance A. A. Baker A. Crosky ~ R. Vodicka* C. Howe ¶ .21 Aircraft Applications and Design Issues S. Dutton A. A. Baker .31 Airworthiness Considerations For B. C. Hoskin Airframe Structures A. A. Baker S. Dutton D. Bond** P. Callus* .41 Three-Dimensionally Reinforced Preforms A. A. Baker and Composites K. H. Leong M. Bannister .51 Smart Structures A. A. Baker S. Galea* .61 Knowledge-Based Engineering, D. Kelly Computer-Aided Design, and Finite K. Wang § Element Analysis Affiliations at the time of drafting: *DSTO, Dept of Defence, Commonwealth of Australia *CRC-ACS Ltd. *Department of Molecular Science, CSIRO §University of New South Wales rekwaH~' De Havilland Aerospace Ltd. **University of Sydney ttRoyal Melbourne Institute of Technology **Royal Australian Air Force Contents Contributors xix Chapter 1 Introduction and Overview 1 1.1 General 1 2.1 Drivers for Improved Airframe Materials 3 3.1 High-Performance Fiber Composite Concepts 3 4.1 Fiber Reinforcements 6 5.1 Matrices 7 6.1 Polymer Matrix Composites 31 7.1 Non-polymeric Composite Systems 31 8.1 Hybrid Metal/PMC Composites 91 References 12 Bibliography 12 Chapter 2 Basic Principles of Fiber Composite Materials 23 1.2 Introduction to Fiber Composite Systems 32 2.2 Micromechanical Versus Macromechanical View of Composites 32 3.2 Micromechanics 52 2.4 Elastic Constants 26 5.2 Micromechanics Approach to Strength 63 2.6 Simple Estimate of Compressive Strength 42 7.2 Off-axis Strength in Tension 54 8.2 Fracture Toughness of Unidirectional Composites 74 References 35 Chapter 3 Fibers for Polymer-Matrix Composites 55 1.3 Overview 55 3.2 Glass Fibers 75 3.3 Carbon Fibers 36 3.4 Boron Fibers 76 5.3 Silicon Carbide 96 3.6 Aramid Fibers 17 7.3 Orientated Polyethylene Fibers 37 8.3 Dry Fiber Forms 74 References 97

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The flow of resin through fiber reinforcement is considered to obey Darcy' s law that states that the velocity of the flow is proportional to the pressure
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