Tooling for Composite Aerospace Structures: Manufacturing and Applications

Cover
Copyright
Dedication
Disclaimer
Preface
List of Acronyms
Chapter 1 - Introduction
	Chapter questions
	References
Chapter 2 - Composite materials
	Chapter outline
	1 - Lamina
	2 - Laminate
	3 - Fundamental property relationships
	4 - Fabrication of composite prepreg
	5 - Types of fiber
		5.1 - Fiber terminology
		5.2 - Fiber materials
			5.2.1 - Fiberglass
			5.2.2 - Kevlar
			5.2.3 - Carbon/Graphite
			5.2.4 - Boron
			5.2.5 - Ceramic
			5.2.6 - Lightning protection
	6 - Matrix materials
		6.1 - Thermosetting resins
			6.1.1 - Curing stages of resins
			6.1.2 - Polyester resins
			6.1.3 - Vinyl ester resin
			6.1.4 - Phenolic resin
			6.1.5 - Epoxy
			6.1.6 - Polyimides
			6.1.7 - Polybenzimidazoles (PBI)
			6.1.8 - Bismaleimides (BMI)
		6.2 - Thermoplastic resins
			6.2.1 - Semicrystalline thermoplastics
			6.2.2 - Amorphous thermoplastics
			6.2.3 - Polycarbonates (PC)
			6.2.4 - Polyamides (nylon, PA-6, PA-12)
			6.2.5 - Polyphenylene sulfide (PPS)
			6.2.6 - Polyetherimide (PEI)
			6.2.7 - Polyether ether ketone (PEEK)
			6.2.8 - Polyetherketoneketone (PEKK)
	7 - Thermal analysis
		7.1 - Glass transition temperature
		7.2 - Material characterization
			7.2.1 - Step 1: thermal stability
			7.2.2 - Step 2: cure kinetics
			7.2.3 - Step 3a: rheological behavior
			7.2.4 - Step 3b: glass transition temperature
			7.2.5 - Step 4: cure shrinkage
			7.2.6 - Step 4b: coefficient of thermal expansion
			7.2.7 - Step 4c: elastic modulus
			7.2.8 - Step 5: constitutive relation
	Chapter questions
	References
Chapter 3 - Tooling materials and processing
	Chapter outline
	1 - Metallic composite tooling materials
	2 - Nonmetallic tooling materials
	3 - Metallic versus nonmetallic
	4 - General processing of tools
		4.1 - Bonding
		4.2 - Surface preparation for bonding
		4.3 - Bond control and types
		4.4 - Failure modes
	5 - Release agents
	6 - Tool material selection study
	Chapter questions
	References
Chapter 4 - Design approach and guidelines
	Chapter outline
	1 - Hot tools
		1.1 - Requirements
		1.2 - Quality control
		1.3 - Residual stress
		1.4 - Tool design best practices
	2 - Cold tools
		2.1 - Assembly
	Chapter questions
	References
Chapter 5 - Manufacturing and quality
	Chapter outline
	1 - Composite manufacturing and tooling
	2 - Composite wing skin manufacturing: a case study
		2.1 - Wing skin fabrication
		2.2 - Design details
		2.3 - Lamination process
		2.4 - Mandrel placement process
		2.5 - Tow filler placement process
		2.6 - Bagging and cure
		2.7 - Postcure evaluation
	3 - Resin transfer molding (RTM)
		3.1 - Process parameters
	4 - Same qualified resin transfer molding (SQRTM)
	5 - Pultrusion
	6 - Compression molding
	7 - Hand layup
	8 - Composite automation
	9 - Stiffening techniques used in composite structures
		9.1 - Hat-stiffened part family
		9.2 - Foam-stiffened part family
		9.3 - Bolted stiffeners
		9.4 - Integrated parts family
	Chapter question
	References
Chapter 6 - Operation of tools
	Chapter outline
	1 - Tool preparation
		1.1 - Internal mold release agent (IMR)
		1.2 - External mold release agent (EMR)
	2 - Transportation and movement
	3 - Metal bonding
	4 - Assembly challenges
	5 - Shimming
	6 - Metrology
	7 - Composite part machining
	8 - Nondestructive inspection (NDI) of composites
		8.1 - Visual inspection
		8.2 - Audible testing
		8.3 - Ultrasonic inspection
			8.3.1 - Through transmission ultrasonic inspection
			8.3.2 - Pulse echo ultrasonic inspection
			8.3.3 - Ultrasonic bond tester inspection
		8.4 - Radiography
		8.5 - Thermography
		8.6 - Neutron radiography
	Chapter questions
	References
Chapter 7 - Modeling and simulation
	Chapter outline
	1 - Process modeling prediction software
		1.1 - FiberSim
		1.2 - Composite fiber modeler
		1.3 - Compro
		1.4 - Aniform
		1.5 - VERICUT composite programming (VCP)
	2 - Modeling and simulation of composite structures and tools
	2.1 - Warpage analysis
	2.2 - Residual stresses
		2.2.1 - Experimental evaluation
		2.2.2 - Fabrication
		2.2.3 - Results
		2.2.4 - Analysis and simulation
	Chapter questions
	References
Chapter 8 - Future lookout
	1 - Additive manufacturing
	2 - Tool-less assembly
	3 - Self-heating tools
	4 - Tool-less part fabrication
	5 - Future predictions
	Chapter questions
	References
Appendix
Index
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