Chapter
Application of aramid fibers
Silicon carbide and boron fibers
1.5.1.3. Other reinforcement configurations
1.5.1.4. Benefits of the fiber form
Compared to bulk form, strength of material in fiber form is superior
Availability of more manufacturing methods
Flexibility in fabrication
1.5.1.5. Limitations of the fiber form
Necessity of high amounts of fibers
To offer improved mechanical properties, reinforcements must be bonded together
The requirement for high fiber volume fraction
Low spacing between fibers
1.5.2.2. Load transfer between the fibers
1.5.2.3. Providing compression strength and modulus
1.5.2.4. Providing shear strength and modulus
1.5.2.5. Protecting the fibers from environmental attack
1.5.2.6. Types of matrix systems
Thermoplastic and thermoset matrix
Improvement of flame resistance
Alter mechanical properties
Colorants, dyes, and pigments
1.5.3.2. Availability of the resin at the fiber surface
1.5.3.3. Matrix and fiber materials compatibility
1.6. Properties of composites
1.6.2. Elastic properties
1.6.3. Thermal properties
1.6.4. Multiply laminates
1.8. Composite materials: Failure behavior
1.10. Aircraft MRO (maintenance, repair, and overhaul)
Chapter 2: Overview of different damage and common repair methods in composite laminates
2.2.1. Processing irregularities
2.2.2. Environmental damages
2.2.3. In-service damages
2.3.1. Matrix imperfections
2.3.5. Gouges, scratches, nicks
2.3.8. Combinations of damages
2.3.9. Damaged fastener holes
2.4. Fabrication defects versus in-service damage
2.4.1. Fabrication defects
2.5.1. Stress-strain curves for fiber and matrix
2.5.2. Failure modes in unidirectional fiber-reinforced composites
2.6. Tension failure of a unidirectional composite ply
2.6.1. Strain-controlled tension failure due to fracture of the fibers
2.6.2. Statistical effects on unidirectional composite strength and failure
2.6.3. Shear-lag load sharing between broken fibers
2.7. Tension failure-Cross-ply composites
2.7.1. Ply discount scheme
2.7.2. Progressive failure
2.7.3. Interfacial stresses
2.7.4. Influence of resin cracking on interlaminar stresses
2.8. Characteristic damage state
2.8.2. Failure modes that alter local stress distribution
2.8.3. Stiffness progress with damage accretion
2.9.1. Unidirectional composites
2.9.2. Cross-ply composites
2.10. Long-term fatigue response
2.11. Compression fatigue failure
2.11.1. Delamination failure
2.11.2. Local microbuckling failure
2.13.1. Resin infusion or injection repair
2.13.5. External patch repair
2.13.6. Structural mechanically fastened repair
2.14. Typical repair procedure
2.14.1. Bolted patch repair schemes
2.14.2. Bonded versus bolted
2.15. Repair disposition events for those damages covered by source documentation, and those that aren't
2.16. Regulatory approval process for damages not covered by source documentation
2.16.1. Contact the OEM for an approved repair
2.16.2. Replace the damaged part
2.16.3. Prepare a specific repair for the damage not covered
Chapter 3: Key stages of adhesively bonded repairs
3.2. Damage assessment: Nondestructive testing
3.2.1.1. The visual inspection process
3.2.1.2. Types of visual inspection
3.2.1.3. Parameters affecting visual inspection
Color/lighting/vision aspects
3.2.1.4. Advantage and disadvantage
Advantage of visual inspection
Disadvantage of visual inspection
3.2.2.3. Output accelerometer signal
3.2.2.4. Influences of damage
3.2.2.5. Greszczuk's equations
3.2.2.6. Grounded spring model
3.2.2.7. Application, advantage, and disadvantage
3.2.3. Dye penetrant testing
3.2.3.1. Advantage and disadvantage
3.2.4. Ultrasonic inspection
3.2.4.1. Types of ultrasonic technique
Application, advantage, and disadvantage
Application, advantage, and disadvantage
Application, advantage, and disadvantage
Application, advantage, and disadvantage
3.2.5.1. Conventional X-radiography technique
3.2.5.2. Computed tomography
3.2.5.3. Enhanced radiographic technique
3.2.5.4. X-ray back-scatter tomography
3.2.5.5. Application, advantage, and disadvantage
3.2.6.1. Thermal pulse thermography
3.2.6.2. Vibrothermography
3.2.6.3. Digital image postprocessing and image enhancement
3.2.6.4. Application, advantage, and disadvantage
3.2.7.1. Conventional shearography
3.2.7.2. Digital shearography
3.2.7.3. Principal of digital shearography
3.2.7.4. Application, advantage, and disadvantage
3.3.1. Conventional machining
3.3.2. Nonconventional machining
3.3.2.1. Abrasive water-jet machining (AWJ)
AWJ machining characteristics of FRPS
Material removal mechanisms
Macro features of AWJ machined surface
Modeling of abrasive flow-water jet in water-jet cutting technique
Modeling of material removal in AWJM method
Phenomenon of formation of kerf
Modeling of energy interactions
Application, advantage, and disadvantage
Laser machining process parameters
Material removal mechanisms
Laser machining characteristics of FRPs
Determination of kerf widths
Location of the laser beam
Slope of the cut kerf (θ)
Material vaporization rate
Advantage and disadvantage
Advantages of laser machining of fiber-reinforced plastics
3.4. Adhesives and surface preparation
3.4.1.1. Addition polymerization
3.4.1.2. Step reaction polymerization
3.4.2. Adhesive materials systems: available adhesives
3.4.2.2. High-temperature adhesives
3.4.2.3. Hot melts adhesives
3.4.2.4. Acrylics (-based thermoplastic adhesives)
3.4.2.5. Cyanoacrylates adhesives
3.4.2.6. Anaerobic acrylic adhesives
3.4.2.7. Urethane adhesives
3.4.2.8. Silicone adhesives
3.4.2.9. Pressure-sensitive adhesives
3.4.2.10. Addition-reaction to polyamide adhesives
3.4.2.11. Latex adhesives
3.4.2.12. Reactive adhesives
3.4.3. Adhesion, wetting, and tack
3.4.3.2. Thermodynamics of adhesion
3.4.4. Bonding mechanisms (or types) in adhesively bonded joints
3.4.4.1. Physical bonding
The electrostatic attraction theory
3.4.4.2. Chemical bonding
3.4.4.3. Diffusion or interdiffusion theory
3.4.4.4. Mechanical bonding
3.4.5. Surface pretreatments
3.4.5.1. Abrasion, grit blasting, and solvent cleaning
3.4.5.2. Peel ply (or tear films)
3.4.5.8. Flame treatments
3.4.5.9. Corona discharge treatment
3.4.5.10. Plasma treatment
3.4.5.11. Laser treatment
3.5.2. Heat transfer and energy balance
3.5.4. Resin flow and consolidation
3.5.7.1. Radiation curing
Radiation heating (microwave, infrared, and laser)
Convection and conduction heating (flame, hot gas, hot shoe, and oven)
Thermal additives based heating
Magnetic additives heating
3.5.7.3. Autoclave curing
Gas stream pressurization
Release films and fabrics
Bleeder and breather plies
Expendable vacuum bagging
Advantages and disadvantages
Curing and consolidation of the part
Advantages and disadvantages
Advantages of the autoclave
Disadvantages of the autoclave
3.5.8. Resin shrinkage, out-of-dimensions and residual stresses
3.5.9. Shrinkage and modulus development
3.5.10. Estimation of residual stresses and changes in dimensions of the component
3.5.11. Out-of-autoclave (OOA) techniques
3.5.11.1. Oven curing method
3.5.11.2. Hot pressing method
Chapter 4: Design, analysis, and durability of composite repairs
4.2. Adhesively bonded repair
4.2.1. Analysis of adhesively bonded repair
4.2.2. Basic adhesive joint properties
4.3. Adhesively bonded joints
4.3.1. Types of adhesive joints
4.3.2. Mechanical durability design principles
4.3.3. Advantages and disadvantages of adhesive bonded joints
4.3.4. Stress analysis of adhesive joints
4.4. Defects in adhesively bonded joints: Modes of failure
4.4.2. Modes of micromechanical damage: Failure characters
4.5. Quality control tests: Assessment of bonding quality
4.5.1. Standard test methods
4.5.1.1. Thick-adherend shear test
4.5.1.2. DCB and wedge-crack tests
4.5.1.3. Short-beam shear test
4.5.2. Novel test methods
4.6. Stress concentrations in adhesively bonded joints
4.6.1. Load transfer in adhesively bonded joints
4.7. Stress analysis using 2D and 3D finite element analysis methods in adhesive joints: Geometrically-linear and nonline ...
4.8. Analysis of adhesively bonded joints: Analytical methods
4.9. Environmental factors
4.10. Mechanics of mechanically fastener repairs
4.10.1. Analysis of bolted repair
4.11.1. ASTM test standards
4.11.1.1. Open-hole and filled-hole tests
4.11.1.3. Pull-through tests
4.11.2. NASA standards for textile composites
4.12. Mechanical design considerations
4.12.1. Design methodology
4.12.2. Material selection (composites and fasteners)
4.12.3. Geometric effects
4.12.4. Preload selection
4.13. Damage modes and failure prediction
4.13.1. Failure owing to static stresses
4.13.2. Failure due to dynamic stresses
4.14. Relaxation in PMC joints
4.14.1. Experimental studies
4.14.2. Finite element studies
4.15. Effects of environmental conditions on bearing strength and failure
4.15.2. Pin connected joints
4.16. Nondestructive evaluation techniques
4.16.1. Electrical resistance change
4.16.3. Vibration techniques
4.16.4. Sonic infrared imaging
4.17. Certification of bonded composite repairs
4.18. Bonded patch repairs overview
4.19. Structural requirements in the certification of airframe structure
4.20. Previous considerations in the certification of repairs
4.21. Proposal for certification of repairs
4.22. Decision chart for primary composite structure
4.23. Repair design-Development of a generic data base
4.24. The representative joint specimen
4.25. Repair design-Generic allowables approach
4.25.1. Some requirements of a repair design process
4.25.2. Application to the repair of composites
4.25.2.1. External patch option
4.26. Validation of the repair as a materials system
4.26.1. Process quality control-Surface treatment
4.26.2. Patch implementation
4.26.3. A proof testing or post implementation validation of repairs
4.26.5. The strain transfer approach
4.27. Damage tolerance of repairs
4.28. Online nondestructive monitoring of repair
4.28.1. Real time AE monitoring technique
4.28.1.1. AE wave analysis
Parameter-based failure mode identification
Failure mode identification using frequency analysis
Failure mode identification through pattern recognition
4.28.1.2. Source location of AE events
4.28.1.3. A generic AE system
4.28.1.4. Pencil lead break test
4.28.1.4.1. HSU-Nielsen source
4.28.1.5. Input parameters for AE acquisition
4.28.2. Digital image correlation
4.28.2.2. Generic DIC methodology
Specimen preparation and locating target feature
Quantifying image correlation
Chapter 5: Safety and precautions
5.2.1.1. Physiological safety
5.2.2. Safety around compressed gases
5.2.3. Safety around hazardous materials
5.2.4. Safety around machine tools
5.3.1. Hearing protection
5.3.2. Foreign object damage
5.3.3. Safety around airplanes
5.3.4. Safety around helicopters
5.4.1. Requirements for fire to occur
5.4.2. Classification of fires
5.4.3. Identifying fire extinguishers
5.4.4. Using fire extinguishers
5.5. Hazard sources and routes of exposure
5.7. Reinforcement fibers
5.8. Dust generation in dry machining
5.9. Aerosol emissions in laser machining
5.10.1. Administrative controls
5.10.2. Engineering controls
5.10.3. Personal protective equipment
5.10.4. Machine tool health
5.11.1. Human reliability analysis
5.11.2. Human error classifications
5.11.3. Responding to human error
5.12. Aviation maintenance tasks and environments
5.12.1. Aviation maintenance and inspection tasks
5.12.2. Organizational context
5.13. Human error in aviation maintenance
5.13.1. Effects of maintenance errors on aircraft equipment
5.13.2. Accidents due to maintenance errors
5.13.3. Other effects of human errors in aviation maintenance
5.13.4. Predicting forms of inspection and maintenance human errors
5.14. Managing human error in aviation maintenance
5.14.1. Detecting human errors in aviation maintenance and inspection
5.14.2. Reporting errors in aviation maintenance and inspection
5.14.2.1. Accident investigations
5.14.2.2. Anonymous incident reports
5.14.2.3. Internal error reporting systems
5.14.3. Proactive error detection methods
5.14.3.2. Subjective evaluations of system reliability
5.14.3.3. Simulation approaches
5.14.4. Addressing human error control in aviation maintenance and inspection
5.14.4.2. Job design and organizational considerations
5.14.4.3. Workspace and ambient environment design
5.14.4.4. Task equipment and information design
5.14.4.6. Comprehensive and integrated approaches to error management
Repair of Polymer Composites
：Methodology, Techniques, and Challenges
( Woodhead Publishing Series in Composites Science and Engineering )
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