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Airframe > Composite Structures > Flashcards

Composite Structures Flashcards

1
Q

The general definition of composites

A

Combinations of two or more materials that differ in composition and form

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2
Q

The description of composite strength to weight ratios

A

High strength to weight ratios for composites

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3
Q

The part of a composite which provides the majority of the structural strength

A

Reinforcing fibers

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4
Q

2 structures that can be used as the core for sandwich structures

A
  1. foam blocks 2. honey comb structures
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5
Q

The material that fiberglass cloth is constructed from

A

silica glass

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6
Q

The disadvantage of using fiber glass compared to using other types of composites

A

Fiberglass has a weaker strength-weight ratio compared to other composite types

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7
Q

The two most common types of fiber glass

A

S- glass E-glass (electric glass)

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8
Q

The 5 most common reinforcing fibers used

A
  1. Fiber glass 2. Aramid (Kevlar) 3. Carbon fiber 4. Ceramic 5. Boron fiber
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9
Q

The reinforcing fibber best suited for use in areas subject to high vibration

A

Aramid

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10
Q

The best typical advantage of Aramid in typical aviation

A

The ability of the this particular reinforcing fiber to flex and absorb stress (such as helicopter blades)

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11
Q

The major disadvantage of Aramid

A

The con of the this particular reinforcing fiber to stretch easily which makes it difficult to repair

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12
Q

The best typical advantage of Carbon Fiber in typical aviation

A

High compression/ bearing strength and stiffness

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13
Q

The major disadvantage of Carbon Fiber

A

The con of the this particular reinforcing fiber to be Cathodic

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14
Q

The type of reinforcing fiber which is critical to keep from coming in contact with aluminium

A

Carbon Fiber

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15
Q

The reinforcing fibber best suited for use in areas subject to high temperatures

A

Ceramic fibers

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16
Q

The reinforcing fibber that will retain most of it’s strength when subjected to intense temperatures

A

Ceramic fibers

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17
Q

The primary reason for arranging fibers in various orientations, in a fiber matrix system

A

To recover some of the lost strength in a composite due to the use of resin which makes the structure more brittle

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18
Q

The primary difference in strength between a sheet of metal and a sheet of composite

A

Metal tends to have the same level of strength in all directions while composites have strength only in the direction of the plies

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19
Q

The reason why wings made out of composites, will have plies running the length of the wing, 45 degrees and 90 degrees

A

A wing is subjected to torsional loads which will run along the wing length, wing chord and every angle inbeween

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20
Q

The 3 names of the orientations of threads of reinforcing fibers

A
  1. Weft/Fill 2. Warp 3. Bias
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21
Q

The description of a pre-impregnated fabrics

A

Fabrics of reinforcing fibers which already have resin contained between the fibers

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22
Q

Orientation of the reinforcing fiber threads in the direction it comes off of the roll

A

Warp definition

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23
Q

Orientation of the reinforcing fiber threads in the direction perpendicular to the warp fibers

A

Weft/ Fill deinition

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24
Q

Orientation of the reinforcing fiber threads diagonal to the warp fibers

A

Bias definition

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25
Q

The types of reinforcing fiber fabric styles

A
  1. Unidirectional 2. Multi-directional
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26
Q

The type of fabric style which is most resistant to “fiber breakout”, and delamination

A

Fabric weave benifits

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27
Q

The purpose of matrix system in a composite structure

A

The holding in place of the reinforcing fibers and transferring of external loads to the fibers

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28
Q

The term for the ability of the matrix to transfer external loads to the reinforcing fibers

A

Interface

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29
Q

The name of the organic polymer which is used as a matrix

A

Resin

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30
Q

5 types of resins

A
  1. Thermoplastic resins 2. Thermosetting resins 3. Polyester resins 4. Epoxy resins 5. Adhesives
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31
Q

The most common method of testing a composite structure for delaminations

A

Coin Tapping testing method

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32
Q

The process that can slow down the cure rate of a resin

A

Refrigeration

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33
Q

Prior to curing, pre-impregnated fabrics typically contain ____ % resin

A

50% resin

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34
Q

During the curing process of a pre-preg, some of the resin bleeds out producing a structure that contains ____% resin and ____% fibers

A

40%, 60%

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35
Q

The way that pre-pregs must be stored

A

Stored in a freezer to prevent curing

36
Q

Another term for a thixotropic agent

A

Another term for a filler

37
Q

Thixatropic agents are added to resins and perform 3 functions

A
  1. Control viscosity 2. Control weight 3. Increase pot life
38
Q

3 common fillers/ thixotropic agents

A
  1. Microballoons 2. Chopped fibers 3. Flox
39
Q

Micro balloons can be manufactured from these two materials

A
  1. Plastic 2. Glass
40
Q

The material of thixotropic that is compatible with resin

A

Glass

41
Q

The chief advantage of using micro balloons as a thixotropic agent

A

Provides greater concentrations of resin in the edges and corners of a structure

42
Q

Chopped fibers and flox primary benefit and how it’s used

A

Adds strength to the structure and is mixed with resin

43
Q

The type of matrices that are still in the developmental phase

A

Metal matrix

44
Q

The means of composite fabrication in which prepreg fibers are directed through a placement device onto a mandrel

A

Filament winding method

45
Q

When a member is bonded between two thin face sheets the structure is termed

A

Sand which structure

46
Q

The greatest type of strength that a sandwich structure has

A

Compression strength

47
Q

The brand name of a widely used honeycomb structure in aviation which is created from paper impregnated material

A

Nomex

48
Q

The general definition of Interply hybrid laminated composite structures

A

two or more layers of different reinforcing material laminated together

49
Q

The direction in which the honeycomb structure can be pulled apart is termed

A

Ribbon direction definition

50
Q

The definition of shelf life for a resin matrix

A

The time that the product is still good in an unopened container

51
Q

The term for when too much resin is applied to a matrix mixture or part

A

Resin rich

52
Q

The term for a when not enough resin is used for a part

A

Resin lean

53
Q

When working the resin into the fibers care should be taken to not distort the_____

A

fabric weave

54
Q

Where the information about the health precautions, hazardous ingredients, flammability, ventilation requirements, spill procedures and transportation/ labeling requirements are found of a part

A

Material Safety Data Sheet (MSDS)

55
Q

The most commonly used method to apply pressure to composite repair

A

Vacuum bagging

56
Q

principle of why vacuum bagging works

A

When pressure is removed from the sealed bag, atmospheric pressure can act on it

57
Q

The manufacturing technique of composite manufacturing which is the most flexible procedure and can be done anywhere

A

wet-lay

58
Q

The term for the method of dissipating the electrical charge on composite structures

A

Bonding

59
Q

3 types of electrical bonding on composites

A
  1. Aluminium wires woven into the top layer of composite fabric 2. Thin sheet of aluminium foil bonded to the outtler layer 3. Aluminum flame sprayed onto the component
60
Q

Composite structure finishes protects the structure from these two things

A
  1. moisture 2. UV light
61
Q

6 types of NDT testing that can be used on composite structures

A
  1. Back light test 2. Tap (coin) test 3. Ultrasonic 4. Radiography (X-ray) 5. Thermography 6. Dye penetrant
62
Q

Description of Back light testing on composite structures

A

Shinning a strong light through the composite structure to look for cracks and delaminations and water

63
Q

What a delamination on a composite structure will look like during a back-light test

A

a bubble or a change in color

64
Q

The step that must be taken prior to inspecting a composite structure with the use of the back-light test method

A

The composite structure must be stripped of all paint prior to

65
Q

The effectiveness of a coin tap test on a composite structure will decrease with

A

an increase in material thickness

66
Q

The most commonly used NDT testing of composite structures

A

Ultrasonic inpection

67
Q

Principle of operation of ultrasonic NDT on composite structure

A

Sound does not travel back to the receiver as fast through a delamination compared to no damage

68
Q

The NDT that can detect water trapped inside a honeycomb structure in a composite structure

A

X-ray, backlight

69
Q

How thermography is used to detect damage on a composite structure

A

Heat is applied to the composite and the damage will show up as temperature gradients using an infrared camera

70
Q

The issue between using liquid dye penetrant and succeeding repairs on composite structures

A

Fibers absorbed by the dye will not bond to new material for a repair

71
Q

In drilling of a composite structure, delamination and breakout is most likely to occur when

A

when the drill pushes out on the other side of the composite structure

72
Q

To reduce the possibility of damage to a composite structure when drilling it, the drill bit must be

A

sharp

73
Q

To prevent delamination and breakout damage of a composite when drilling through it, drilling should be done with

A

a wooden block behind the surface

74
Q

In drilling a composite structure blindly, and the backside of the structure isn’t accessible for a wooden block, this precaution must be done

A

measure precisely the depth of the drill bit

75
Q

The best material/ type of drill-bit to use in drilling through composites

A

carbide drills

76
Q

Operation if a water-jet cutter

A

water is applied with a pressure of 50,000 psi through a pinhole nozzle

77
Q

The literature to find all the material required for a repair on a composite material

A

Structural Repair Manual (SRM)

78
Q

The only method which is used to remove the surface finish on a composite structure

A

Sanding

79
Q

The instrument used to remove the damaged part of the composite structure, especially structures with honey-comb cores

A

Router

80
Q

The 3 steps in Step Cutting damage out of a composite structure

A
  1. Outline the entire damaged area that must be cutout and removed 2. Expand the repair radius (if circular) by 1/2 an inch for every ply that must be repaired 3. Extend the radius by an additional one-inch if an overlap patch is called for
81
Q

Which numer is the Ribbon Direction

A

2

82
Q

The 4 basic types of composite repairs

A
  1. Bolted metal
  2. Bonded metal
  3. Resin injection
  4. Lamination of new plies
83
Q

The main reason why bolted or bonded patches are not perfered means of composite material repair

A

Bolted and bonded patches do not restore structure to orignal strength

84
Q

The most desired type of compiste structure repair

A

Lamination of new repair plies

85
Q

The 4 major types of damage to composite materials

A
  1. Cosmetic
  2. Impact
  3. Cracks
  4. Holes
86
Q

Description of the water-break test and when its useful

A

Prior to bonding, a means of cleaning the surface

Flushing the part with room temperature water and looking for water beads on the surface which indicate more cleaning is required

Airframe (22 decks)

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