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Chapter 1 Introduction to Composite Materials and Processes3

1.1 Laminates3

1.2 Fibers5

1.3 Matrices9

1.4 Product Forms12

1.5 Overview of Fabrication Processes17

1.6 Advantages and Disadvantages of Composites25

1.7 Applications32

1.8 Summary35

1.9 Acknowledgement35

1.10 References37

Chapter 2 Fibers and Reinforcements40

2.1 Fiber Terminology40

2.2 Glass Fibers41

2.3 Aramid Fibers44

2.4 Ultra-High Molecular Weight Polyethylene（UHMWPE） Fibers45

2.5 Carbon and Graphite Fibers46

2.6 Woven Fabrics49

2.7 Reinforced Mats54

2.8 Chopped Fibers55

2.9 Prepreg Manufacturing56

2.10 Summary61

2.11 References62

Chapter 3 Thermoset Resins65

3.1 Thermosets65

3.2 Polyester Resins66

3.3 Epoxy Resins67

3.4 Bismaleimide Resins76

3.5 Cyanate Ester Resins78

3.6 Polyimide Resins79

3.7 Phenolic Resins82

3.8 Toughening Approaches83

3.9 Physiochemical Characterization and Quality Control91

3.10 Chemical Testing91

3.11 Rheological Testing93

3.12 Thermal Analysis95

3.13 Glass Transition Temperature96

3.14 Summary99

3.15 References100

Chapter 4 Cure Tooling104

4.1 General Considerations104

4.2 Thermal Management110

4.3 Tool Fabrication118

4.4 Summary129

4.5 References130

Chapter 5 Ply Collation132

5.1 Prepreg Control132

5.2 Tool Preparation133

5.3 Manual Lay-Up134

5.4 Ply Collation138

5.5 Flat Ply Collation and Vacuum Forming141

5.6 Automated Tape Laying144

5.7 Filament Winding148

5.8 Fiber Placement158

5.9 Vacuum Bagging163

5.10 Summary171

5.11 References173

Chapter 6 Curing180

6.1 Cure of Epoxy Composites180

6.2 Theory of Void Formation184

6.3 Hydrostatic Resin Pressure Studies190

6.4 Chemical Composition Variables198

6.5 Net and Low Flow Resin Systems199

6.6 Resin and Prepreg Variables200

6.7 Lay-Up Variables201

6.8 Debulking Operations203

6.9 Caul Plates and Pressure Intensifiers206

6.10 Condensation Curing Systems207

6.11 Residual Curing Stresses210

6.12 Exotherm217

6.13 In-Process Cure Monitoring218

6.14 Cure Modeling219

6.15 Summary219

6.16 References220

Chapter 7 The Interaction of Chemical Composition and Processing on Laminate Quality226

7.1 Prepreg Physical Properties226

7.2 Chemical Properties227

7.3 Thermal Properties229

7.4 Rheological Properties230

7.5 Laminate Evaluations231

7.6 Summary238

7.7 References239

Chapter 8 Adhesive Bonding and Integrally Cocured Structures242

8.1 Adhesive Bonding242

8.2 Advantages of Adhesive Bonding242

8.3 Disadvantages of Adhesive Bonding244

8.4 Theory of Adhesion244

8.5 Joint Design245

8.6 Adhesive Testing250

8.7 Surface Preparation251

8.8 Epoxy Adhesives258

8.9 Bonding Procedures262

8.10 Sandwich Structures267

8.11 Honeycomb Core269

8.12 Honeycomb Processing277

8.13 Balsa Wood285

8.14 Foam Cores285

8.15 Syntactic Core288

8.16 Inspection289

8.17 Integrally Cocured Structure290

8.18 Summary298

8.19 References299

Chapter 9 Liquid Molding306

9.1 Preform Technology306

9.2 Fibers307

9.3 Woven Fabrics308

9.4 Three-Dimensional Woven Fabrics309

9.5 Knitted Fabrics311

9.6 Stitching312

9.7 Braiding314

9.8 P4A Process320

9.9 Random Mat322

9.10 Preform Advantages323

9.11 Preform Disadvantages325

9.12 Integral Structures Made by Textile Processes325

9.13 Preform Lay-Up327

9.14 Resin Injection331

9.15 Curing335

9.16 RTM Tooling336

9.17 Resin Transfer Molding Defects338

9.18 Resin Film Infusion341

9.19 Vacuum Assisted Resin Transfer Molding349

9.20 Summary354

9.21 References355

Chapter 10 Thermoplastic Composites358

10.1 The Case for Thermoplastic Composites358

10.2 Thermoplastic Composite Matrices360

10.3 Product Forms368

10.4 Consolidation369

10.5 Thermoforming379

10.6 Joining390

10.7 Summary395

10.8 References396

Chapter 11 Commercial Processes400

11.1 Lay-Up Processes400

11.2 Compression Molding412

11.3 Injection Molding420

11.4 Structural Reaction Injection Molding430

11.5 Pultrusion432

11.6 Summary437

11.7 References437

Chapter 12 Assembly440

12.1 Trimming and Machining Operations440

12.2 General Assembly Considerations445

12.3 Hole Drilling448

12.4 Fastener Installation457

12.5 Sealing467

12.6 Painting468

12.7 Summary469

12.8 References469

Chapter 13 Nondestructive Inspection and Repair473

13.1 Nondestructive Inspection473

13.2 Visual Inspection473

13.3 Ultrasonic Inspection474

13.4 Portable Equipment483

13.5 Radiographic Inspection483

13.6 Thermographic Inspection490

13.7 Repair492

13.8 Fill Repairs492

13.9 Injection Repairs493

13.10 Bolted Repairs497

13.11 Bonded Repairs501

13.12 Summary511

13.13 References511

Appendix A- Metric Conversions513