Fiber-reinforced polymers aerospace

As discussed above, the nautical field is one of the most important fields in which epoxy resins are used, mainly as matrices for fiber-reinforced polymers but also as adhesives and paints. Unlike aerospace applications, in which epoxy resins have been the norm for years, in the nautical field nowadays more than 90% of pleasure boats under 60 feet are still made with polyester resin, thanks to their lower costs. In fact epoxy resins are more expensive than vinyl ester resins and the latter are about twice as expensive as polyester ones. Since the resin can constitute up to half the weight of a composite component, this price difference has a significant impact on the cost of the laminate. 

The focus of this chapter has been to give a general overview of the many manufacturing processes available today for the manufactrrre of fiber reinforced polymer composites. Most of the technologies discussed are subject to continuous improvements as manufacturers from the aerospace, automotive, construction and consumer products industries strive to improve manufacturing costs and overall product quality. 

Thermal oxidative degradation of carbon-fiber-reinforced polymer composites has been intensively investigated because these materials are fit for aerospace applications. A comparative kinetic study has been undertaken on the gravimetric curves... 

La Mantia FP, Morreale (2011) Green composites a brief review. Compos A 42 579-588 Li Y, Li N, Gao J (2013) Tooling design and microwave curing technologies for the manufacturing of fiber-reinforced polymer composites in aerospace applications. Int J Adv Manuf Technol 70 (l ) 591-606... 

Fiber-reinforced composites contain strong fibers embedded in a continuous phase. They form the basis of many of the advanced and space-age products. They are important because they offer strength without weight and good resistance to weathering. Typical fibers are fiberous glass, carbon-based, aromatic nylons, and polyolefins. Typical resins are polyimides, polyesters, epoxys, PF, and many synthetic polymers. Applications include biomedical, boating, aerospace and outer space, sports, automotive, and industry. 

Unlike ductile metals, composite laminates containing fiber-reinforced thermosetting polymers do not exhibit gross ductile yielding. However, they do not behave as classic brittle materials, either. Under a static tensile load, many of these laminates show nonlinear characteristics attributed to sequential ply failures. One of the difficulties, then, in designing with laminar composites is to determine whether the failure of the first ply constitutes material failure, termed first-ply failure (FPF), or if ultimate failure of the composite constitutes failure. In many laminar composites, ultimate failure occurs soon after first ply failure, so that an FPF design approach is justified, as illustrated for two common laminar composites in Table 8.9 (see Section 5.4.3 for information on the notations used for laminar composites). In fact, the FPF approach is used for many aerospace and aircraft applications. 

FRP materials are made up of the polymer and reinforcing fibers. The polymer is typically a thermoset polymer thermoplastics can be used as well. Some typical thermoset polymers used are epoxy resins, unsaturated polyester resins, epoxy vinyl ester resins, phenolic resins, and high performance aerospace resins such as cyanate esters, polyimides, and bismaleimides. These resins... 

Organic matrices are divided into thermosets and thermoplastics. The main thermoset matrices are polyesters, epoxies, phenolics, and polyimides, polyesters being the most widely used in commercial applications (3,4). Epoxy and polyimide resins are applied in advanced composites for structural aerospace applications (1,5). Thermoplastics Uke polyolefins, nylons, and polyesters are reinforced with short fibers (3). They are known as traditional polymeric matrices. Advanced thermoplastic polymeric matrices like poly(ether ketones) and polysulfones have a higher service temperature than the traditional ones (1,6). They have service properties similar to those of thermoset matrices and are reinforced with continuous fibers. Of course, composites reinforced with discontinuous fibers have weaker mechanical properties than those with continuous fibers. Elastomers are generally reinforced by the addition of carbon black or silica. Although they are reinforced polymers, traditionally they are studied separately due to their singular properties (see Chap. 3). 

In the aerospace industry, resinous polymers encompass a wide variety of hardware applications for aircraft, missiles, and space structures. In aircraft, resins are used as a matrix material for primary (flight-dependent) and secondary fiber-reinforced composite (FRC) structures, adhesives for the bonding of metal and composite hardware components, electronic circuit board materials, sealants, and radomes. Missile applications include equipment sections, motor cases, nose cones, cartjon-carbon composites for engine nozzles, adhesive bonding, and electronics. As the exploration of outer space intensifies, applications will become even more exotic. FRC will be used to construct telescopes, antennas, satellites, and eventually housing and other platform structures where special properties such as weight, stiffness, and dimensional stability are important. 

This chapter will deal with the chemistry and applications of epoxies, phenolics, urethanes, and a variety of current vogue high-temperature polymers. Applications in fiber-reinforced plastics will be discussed in the individual sections on resin chemistry where appropriate. Separate sections will deal with adhesives and sealants. Adhesives are most important because, as early history demonstrates, they led the way to the application of resins in aerospace. A section is also included on silicone and polysulfide sealants. Although these materials are elastomers rather than resins, no discussion of aerospace polymers would be complete without some mention. Some major thermosetting polymers have been omitted from this review. Among these are the unsaturated polyesters, melamines, ureas, and the vinyl esters. Although these products do find their way into aerospace applications, the uses are so small that a detailed discussion is not warranted. 

Another characteristic property of polymers, namely their high specific stiffness and strength (which are due to their low density, especially when used in fiber-reinforced composite materials), has led to the use of polymers in transport applications, especially in aerospace industries, where weight saving is of vital importance and materials cost is secondary. However, here again many applications also demand high temperature resistance. 

Fiber reinforced ceramic matrix composites (CMCs) are under active consideration for large, complex high temperature structural components in aerospace and automotive applications. The Blackglas resin system (a low cost polymer-derived ceramic [PDC] technology) was combined with the Nextel 312 ceramic fiber (with a boron nitride interface layer) to produce a sihcon oxycarbide CMC system that was extensively characterized for mechanical, thermal, and electronic properties and oxidation, creep mpture, and fatigue. A gas turbine tailcone was fabricated and showed excellent performance in a 1500-hour engine test. 

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