Composite Materials for Aircraft Structures Second Edition

602 Pages·2008·10.02 MB·English

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
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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