Chapter 1 Introduction to Composite Materials and Processes

1.1 Laminates

1.2 Fibers

1.3 Matrices

1.4 Product Forms

1.5 Overview of Fabrication Processes

1.6 Advantages and Disadvantages of Composites

1.7 Applications

1.8 Summary

1.9 Acknowledgement

1.10 References

Chapter 2 Fibers and Reinforcements

2.1 Fiber Terminology

2.2 Glass Fibers

2.3 Aramid Fibers

2.4 Ultra-High Molecular Weight Polyethylene（UHMWPE） Fibers

2.5 Carbon and Graphite Fibers

2.6 Woven Fabrics

2.7 Reinforced Mats

2.8 Chopped Fibers

2.9 Prepreg Manufacturing

2.10 Summary

2.11 References

Chapter 3 Thermoset Resins

3.1 Thermosets

3.2 Polyester Resins

3.3 Epoxy Resins

3.4 Bismaleimide Resins

3.5 Cyanate Ester Resins

3.6 Polyimide Resins

3.7 Phenolic Resins

3.8 Toughening Approaches

3.9 Physiochemical Characterization and Quality Control

3.10 Chemical Testing

3.11 Rheological Testing

3.12 Thermal Analysis

3.13 Glass Transition Temperature

3.14 Summary

3.15 References

Chapter 4 Cure Tooling

4.1 General Considerations

4.2 Thermal Management

4.3 Tool Fabrication

4.4 Summary

4.5 References

Chapter 5 Ply Collation

5.1 Prepreg Control

5.2 Tool Preparation

5.3 Manual Lay-Up

5.4 Ply Collation

5.5 Flat Ply Collation and Vacuum Forming

5.6 Automated Tape Laying

5.7 Filament Winding

5.8 Fiber Placement

5.9 Vacuum Bagging

5.10 Summary

5.11 References

Chapter 6 Curing

6.1 Cure of Epoxy Composites

6.2 Theory of Void Formation

6.3 Hydrostatic Resin Pressure Studies

6.4 Chemical Composition Variables

6.5 Net and Low Flow Resin Systems

6.6 Resin and Prepreg Variables

6.7 Lay-Up Variables

6.8 Debulking Operations

6.9 Caul Plates and Pressure Intensifiers

6.10 Condensation Curing Systems

6.11 Residual Curing Stresses

6.12 Exotherm

6.13 In-Process Cure Monitoring

6.14 Cure Modeling

6.15 Summary

6.16 References

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

7.1 Prepreg Physical Properties

7.2 Chemical Properties

7.3 Thermal Properties

7.4 Rheological Properties

7.5 Laminate Evaluations

7.6 Summary

7.7 References

Chapter 8 Adhesive Bonding and Integrally Cocured Structures

8.1 Adhesive Bonding

8.2 Advantages of Adhesive Bonding

8.3 Disadvantages of Adhesive Bonding

8.4 Theory of Adhesion

8.5 Joint Design

8.6 Adhesive Testing

8.7 Surface Preparation

8.8 Epoxy Adhesives

8.9 Bonding Procedures

8.10 Sandwich Structures

8.11 Honeycomb Core

8.12 Honeycomb Processing

8.13 Balsa Wood

8.14 Foam Cores

8.15 Syntactic Core

8.16 Inspection

8.17 Integrally Cocured Structure

8.18 Summary

8.19 References

Chapter 9 Liquid Molding

9.1 Preform Technology

9.2 Fibers

9.3 Woven Fabrics

9.4 Three-Dimensional Woven Fabrics

9.5 Knitted Fabrics

9.6 Stitching

9.7 Braiding

9.8 P4A Process

9.9 Random Mat

9.10 Preform Advantages

9.11 Preform Disadvantages

9.12 Integral Structures Made by Textile Processes

9.13 Preform Lay-Up

9.14 Resin Injection

9.15 Curing

9.16 RTM Tooling

9.17 Resin Transfer Molding Defects

9.18 Resin Film Infusion

9.19 Vacuum Assisted Resin Transfer Molding

9.20 Summary

9.21 References

Chapter 10 Thermoplastic Composites

10.1 The Case for Thermoplastic Composites

10.2 Thermoplastic Composite Matrices

10.3 Product Forms

10.4 Consolidation

10.5 Thermoforming

10.6 Joining

10.7 Summary

10.8 References

Chapter 11 Commercial Processes

11.1 Lay-Up Processes

11.2 Compression Molding

11.3 Injection Molding

11.4 Structural Reaction Injection Molding

11.5 Pultrusion

11.6 Summary

11.7 References

Chapter 12 Assembly

12.1 Trimming and Machining Operations

12.2 General Assembly Considerations

12.3 Hole Drilling

12.4 Fastener Installation

12.5 Sealing

12.6 Painting

12.7 Summary

12.8 References

Chapter 13 Nondestructive Inspection and Repair

13.1 Nondestructive Inspection

13.2 Visual Inspection

13.3 Ultrasonic Inspection

13.4 Portable Equipment

13.5 Radiographic Inspection

13.6 Thermographic Inspection

13.7 Repair

13.8 Fill Repairs

13.9 Injection Repairs

13.10 Bolted Repairs

13.11 Bonded Repairs

13.12 Summary

13.13 References

Appendix A- Metric Conversions