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AIRCRAFT COMPOSITE STRUCTURE REPAIR

Manufacturing Process

Introduction to Composite Materials 1 ATA 51 - Aircraft Composite Repair

AIRCRAFT COMPOSITE STRUCTURE REPAIR AIRCRAFT COMPOSITE STRUCTURE REPAIR

Continuous void free resin matrix

Maintain accurate fiber architecture

Reliable and repeatable process

Specific resin content

Aerospace Manufacturing

ATA 51 - Aircraft Composite Repair

Introduction to Composite Materials 2

Manufacturing process


Manufacturing Technique

Hand lay up

Automated process

Filament Winding

Liquid Resin infusion

Thermoplastic





• Hand lay up







Wet Hand Lay Up – Vaccum Bag

Dry fibers are saturated with mixed resin until all are soaked. Bagging materials are placed on the fabricated item and sealed it to vacuum the air out. The atmospheric pressure in pushed on the part during curing.




Wet Hand Lay Up – Vaccum Bag




Wet Hand Lay Up – Reusable Bag

Silicone based material

Instead of using bagging materials, a mix part silicone materials are poured on the mold and cured following the mold’s shape. Once the fabricated items are soaked with the resin, the silicone bag is placed on the part and let to cure.




Dry Layup – PrePreg Material

Autoclave curing, high temperature with 4~6 bar pressure

Oven curing, high temperature but with 1 bar atmospheric pressure. Known as out of autoclave curing (OOA)




Dry Layup – PrePreg Material

Thermocouple

Vacuum Bag Film Breather/ Bleeder Release Film (with or without perforations) Peel ply Laminate Mold Release

Autoclave/ Oven hose Quick Disconnect Vac Valve

Pressure sensitive tape

CTFE connection fitting

Masterbar composite Support structure

Vacuum bag sealant tape




Dry Layup – Heat Blanket System

Used only during aircraft composite repair. Localized heat. Ease of mobility. High temperature curing with 22 inHg or 1bar of vacuum.




Dry Layup – Heat Blanket System

Thermocouples Sealant tape

Flash tape or polyester disc

Core ply adhesive

Peel ply

Release film perforated or teflon coated fiberglass porous

Silicone rubber heat blanket

Breather/ bleeder

Nylon Bagging film

Release film non perforated or teflon

coated fiberglass/ non-porous

Caul plate (optional)

Fiberglass bleeder cloth

Repair plies

Vacuum hose/ sniffer assembly

Vacuum hose/




Fibre is chopped in a hand-held gun and fed into a spray of catalysed resin directed at the mould. The deposited materials are left to cure under standard atmospheric conditions.

Chopped Spray


Chopped Spray

Resin

Catalyst

Mixer control

Chopper gun

Swivel arm

Resin outlet

Fiber cutter




Chopped Spray


Filament Winding

Continuous and Finite fabricated

part.

Suitable to make circular or oval

shapes

Pultrusion

Continuous and infinite fabricated part with more

cross section pattern available.

Fiber alignment along pulling direction

Instant curing

Pull-winding

Combination of filament winding and pultrusion

Fiber alignment are braided type orientation

Instant curing





Advantages

Fast & economical lay out

Controlled resin content

Low material cost and no secondary process

Fibers can be laid to match loading direction

Disadvantages

Limited to convex shaped

Cannot cannot be laid along the length of the part

Mandrel cost is high depend on size and shape

Internal surface is unmolded- aesthetic







Fibre tows are passed through a resin bath before being wound onto a mandrel in a variety of orientations, controlled by the fibre feeding mechanism, and rate of rotation of the mandrel.

Filament Winding




Filament Winding


• Winding Patterns Manufacturing Process


Filament Winding




Fibres are pulled from a creel through a resin bath and then on through a heated die. The die completes the impregnation of the fibre, controls the resin content and cures the material into its final shape as it passes through the die

Pultrusion

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Manufacturing Process Pultrusion




Similar to pultrusion, the fibres are pulled from a creel through a resin bath and then on through a braided arrangement heated die. The die completes the impregnation of the fibre, controls the resin content and cures the material into its circular shape as it passes through the die

Pull Winding


Vacuum Assisted Resin Transfer Molding

•Draw resin to mold cavity by vacuuming the air to vacuum pot

•A380 Vertical tail plain component, A330-200 Fin box rib

Resin Transfer Molding

•Resin is injected to closed mold at the same time vacuum is drawn out

•Fittings, rib, aileron spar

Resin Film infusion

•Layer of precatalysed resin film and dry reinforcement applied on mold and cured at high temperature. Resin film will melt and infused to the dry fabric

•A380 Aft pressure bulkhead, A380 wing lower access panels







Fabrics are laid up as a dry stack of materials in between male and female mold. Resin is injected to impregnate the fabric between 2 to 6 bars.




Pump controller

Catalyst container

Acetone container

Resin mixture outlet Resin inlet

Ratio pump




Fabrics are laid up as a dry stack of materials and covered by vacuum bag. The whole dry stack is then vacuum bagged, and once bag leaks have been eliminated, resin is allowed to flow into the laminate through the pulling of vacuum

Vacuum infusion/ Resin Infusion

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Fabrics are laid up as a dry stack of materials and covered by vacuum bag. The whole dry stack is then vacuum bagged, and once bag leaks have been eliminated, resin is allowed to flow into the laminate through the pulling of vacuum. A low viscosity resin is required in order to run this fabrication technique to eliminate wash out effect.

Vacuum infusion/ Resin Infusion


Resin Film Infusion

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Dry fabrics are laid up interleaved with layers of semi-solid resin film supplied on a release paper. The lay-up is vacuum bagged to remove air through the dry fabrics, and then heated to allow the resin to first melt and flow into the air-free fabrics, and then after a certain time, to cure.


Compression Molding

A preform substance is placed in a hydraulic press with heated platens. The preforms can be in the form of Dough Molding Compound (DMC), Sheet molding compound (SMC) or even pre-impregnated materials. The heated platens shorten the curing thus increase the cycle time of a product.


Compression Molding


Automated Tape Laying

Flat surface,

Automated Fiber Placement

Curvature





• Automated fiber Placement




ATL machinery lays fibre down in the form of pre-preg unidirectional tape or continuous strips of fabric, rather than single tows. Usually for a big and long flat panel which a high consistency and accuracy are needed. The uncured part is still cured in a temperature assisted environment such as autoclave

Manufacturing Process Automated Tape Laying


Automated Tape Laying


AFP was developed as a solution automating lay up of complex 3-D shapes with concave and other asymmetrical configurations. It combines the motion characteristics of a filament winder and the fibre lay-up attributes of a tape laying machine therefore it can fabricate any complex structures. Heat assisted curing is still required once the placement process has finished.

Manufacturing Process Automated Fiber Placement


Manufacturing Process Automated Fiber Placement

Fixed mold with contour shape. Rotating mold and movable head Special placement for openings.




Manufacturing method 1 3 2

1 3 2

1 3 2

Laminating and curing of skins and spars

Adhesive film

Honeycomb core Fit to size

Inner and outer skins Layers of Fabric or Tape

Co-curing Process

Co-bonding Process

Secondary bonding multiphase process

Inner skin 1 uncured Outer skin 2 uncured

Both skins 1 and 2 are cured together with honeycomb core 3, effectively created a single part

Inner skin 1 cured Outer skin 2 uncured

Components 1 and 3 bonded during cure cycle of component 2

Individual skins 1. 2 and spars are cured

In a second operation, honeycomb core 3 and individuals skins 1,2 and

devices are bonded together Note: 1 & 2 are cured by using autoclave at 7 bar




Manufacturing methods

1

2

1

2

1

2

Adhesive (optional)

Adhesive

Co-curing Process

Co-bonding Process

Secondary bonding multiphase process

Component 1 uncured Component 2 uncured

Components cure together, effectively creating a single part

Component 1 cured Component 2 uncured

Component 1 bonded during cure cycle of component 2

Component 1 cured Component 2 cured

Components bonded together with separate bonding

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