DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF ENGINEERING

TEZPUR UNIVERSITY, TEZPUR, ASSAM

SESSIONAL TEST 2 - (ME434) REPORT

APPLICATION OF COMPOSITE MATERIALS IN THE

AEROSPACE INDUSTRY

SUBMITTED BY:

Ronak Kumar Kushwaha Bhaskarjya Jyoti Deka

ROLL NO: MEB20006 ROLL NO: MEB20008

B. TECH IN MECHANICAL ENGINEERING

2020-2024
 TABLE OF CONTENTS

PARTICULARS PAGE NO
1 ABSTRACT 1
2 INTRODUCTIONS 1
3 ADVANTANGES 2
4 DISADVANTAGES 3
5 COMPOSITES IN AIRCRAFTS 4
5.1 WINGS 5
5.2 TAIL ASSEMBLY 5
5.3 ENGINE COMPONENTS 6
6 COMPOSITES IN SPACE CRAFTS 7
7 FUTURE OF COMPOSTIE MATERIALS IN 8
AEROSPACE INDUSTRIES
8 CONCLUSIONS 9

9 REFERENCES 9
 ABSTRACT
The use of composite materials in aerospace can be traced back to the early 20th
century when early versions of composites made from natural materials like straw,
animal hides, and wood were used in aircraft construction. However, it was not until
the mid-20th century that the use of synthetic composite materials in aerospace
gained widespread attention. The development of synthetic composite materials in
the 1950s and 1960s, such as fiberglass and carbon fibre reinforced plastics, led to
their adoption in aerospace applications due to their high strength-to-weight ratio,
fatigue resistance, and durability. The first commercial aircraft to use composite
materials was the Boeing 727 in 1963, which used fiberglass in its empennage. In the
following decades, the use of composite materials in aerospace continued to
increase, with advanced composites like carbon fibre reinforced plastics becoming
more widely used in primary structures like wings and fuselages. Today, composite
materials are used extensively in all types of aircraft, from small general aviation
planes to commercial airliners and military jets.

INTRODUCTION
The aerospace sector's unceasing need to improve the performance of civil and
military aircraft drives continuous advancements in high performance structural
materials. One type of materials that is very important in both present-day and
future aerospace components is composite materials.

Due to their remarkable strength and stiffness-to-density ratios, as well as great

physical characteristics, composite materials are very appealing for use in aviation
and aerospace applications.

A composite material typically comprises of quite strong, stiff fibres in a durable resin
matrix. Both wood and bone are made of natural composite materials,
hydroxyapatite particles in a collagen matrix for bone and cellulose fibres in a lignin
matrix for wood. Carbon- and glass-fibre reinforced plastic (CFRP and GFRP,
respectively) are two more well-known artificial composite materials that are used in
the aerospace and other industries. These materials are made of carbon and glass
fibres, both of which are stiff and strong (for their densities), but brittle, and are
embedded in a polymer matrix that is tough but not particularly stiff or strong.
 ADVANTAGES
1. High Strength-to-Weight Ratio: Composites offer a high strength-to-weight ratio,
making them significantly lighter than traditional materials like aluminium and steel.
This weight reduction leads to fuel savings and increased range and payload
capabilities.
2. Corrosion Resistance: Composites are highly resistant to corrosion and do not rust or
deteriorate like traditional metals. This is essential in aerospace, where aircraft are
exposed to harsh environments and extreme temperatures.
3. Design Flexibility: Composites offer greater design flexibility than traditional
materials, allowing for the creation of complex shapes and structures. This allows for
the development of advanced aerodynamic designs that can improve aircraft
performance.
4. Fatigue Resistance: Composites are resistant to fatigue failure, making them ideal for
use in aerospace applications where cyclic loading is a concern. This makes them
ideal for use in critical structural components like wings and fuselages.
5. Impact Resistance: Composites can absorb more energy than traditional materials,
making them better able to withstand impacts and survive extreme events like bird
strikes.
6. Reduced Maintenance: Composites require less maintenance than traditional
materials, reducing maintenance costs and downtime for aircraft. They are also
easier to repair, with damage often being limited to the affected area and not
affecting the entire structure.
7. Lower Manufacturing Costs: While the initial investment in composite materials can
be high, the overall manufacturing costs can be lower than traditional materials. This
is due to the ease of automation in composite manufacturing processes, which leads
to higher production rates and lower labour costs.
8. Improved Heat Resistance: Composites can withstand high temperatures without
degrading, making them ideal for use in applications like engine components and
thermal protection systems.
9. Enhanced Stealth Capabilities: Composites can reduce the radar signature of aircraft,
making them ideal for military applications where stealth is important.
10. Environmentally Friendly: Composites are more environmentally friendly than
traditional materials. They can be recycled, reducing waste and environmental
impact. Additionally, their lighter weight leads to reduced fuel consumption and
lower emissions, making them an attractive option for environmentally conscious
airlines.
 DISADVANTAGES
1. High Cost: Composite materials can be expensive, especially when compared
to traditional materials like aluminium or steel. This can increase the cost of
manufacturing aircraft, as well as the cost of maintenance and repair.
2. Difficulty in Inspecting and Repairing: Composite materials can be difficult to
inspect for damage or defects. Repairing damaged composites can also be
challenging and may require specialized knowledge and equipment.
3. Susceptibility to Environmental Factors: Composite materials can be
susceptible to environmental factors like moisture, heat, and UV radiation,
which can degrade their performance over time.
4. Limited-Service Life: Composite materials may have a limited-service life,
particularly when exposed to harsh environments. This can lead to a need for
more frequent replacement or repair than traditional materials.
5. Flammability: Composite materials can be flammable and may require special
precautions to minimize the risk of fire or explosions.
6. Variation in Properties: Composite materials can have variation in properties
due to differences in manufacturing processes, leading to potential
differences in performance between components.
7. Health Concerns: Some composite materials can pose health risks to workers
involved in their manufacturing or repair due to the release of hazardous
chemicals or dust particles.
8. Difficulty in Recycling: Composite materials can be difficult to recycle,
particularly if they are made from multiple layers of different materials.
9. Limited Availability: Composite materials may not be readily available in some
areas, particularly in remote or underdeveloped regions of the world.
10. Impact on Environment: The manufacturing and disposal of composite
materials can have an impact on the environment, particularly if they are not
properly disposed of or recycled.
 COMPOSITES IN AIRCRAFTS
Composite materials are becoming increasingly popular in the aircraft industry due to
their superior mechanical properties, lightweight nature, and resistance to corrosion.
The unique combination of strength and lightness offered by composites make them
an attractive choice for designers and engineers in the aircraft industry. Here are the
various applications of composite materials in the aircraft industry.

There are many different types of composites used in aircraft, and the specific
materials used will depend on the design and requirements of the aircraft. However,
some common types of composites used in aircraft include:

1. Carbon fibre reinforced polymer (CFRP): This is one of the most commonly
used composite materials in aircraft. It consists of a carbon fibre
reinforcement in a polymer matrix, and it is known for its high strength-to-
weight ratio, excellent fatigue resistance, and stiffness. CFRP is used in a wide
range of aircraft components, including wings, fuselages, and tail assemblies.
2. Glass fibre reinforced polymer (GFRP): This composite material is similar to
CFRP, but it uses glass fibres as the reinforcement instead of carbon fibres.
GFRP is often used in less critical areas of the aircraft, such as fairings and non-
load-bearing components.
3. Kevlar reinforced polymer: Kevlar is a high-strength aramid fibre that is often
used as a reinforcement in polymer matrix composites. It is known for its
excellent impact resistance and toughness, and it is often used in areas of the
aircraft that are subject to bird strikes or other impacts.
4. Ceramic matrix composites (CMCs): CMCs are made up of ceramic fibres or
particles in a ceramic matrix. They are known for their high temperature
resistance and are often used in hot sections of aircraft engines, such as
turbine blades and shrouds.
5. Metal matrix composites (MMCs): MMCs are composite materials that
incorporate metal fibres or particles in a metal matrix. They are known for
their high strength and stiffness and can be used in aircraft components such
as landing gear and engine components.
WINGS
Composites are widely used in the construction of aircraft wings due to their high strength-
to-weight ratio and excellent fatigue resistance. Here are some specific ways that
composites are used in wings:
1. Wing Spars: The spar of an aircraft wing is typically one of the primary load-bearing
structures, and it is often made from composite materials for their high strength-to-
weight ratio. Carbon fibre reinforced polymer (CFRP) is a commonly used material
for this application.

CFRP is a composite material that consists of carbon fibres embedded in a polymer

matrix, such as epoxy resin. It has excellent mechanical properties, including high
strength, stiffness, and fatigue resistance, which make it well-suited for use in the
spar of an aircraft wing. Additionally, CFRP has a low density, which helps to reduce
the overall weight of the wing and improve the fuel efficiency of the aircraft.

2. Wing Skins: The skin of an aircraft wing is the outermost layer that covers the wing
and provides a smooth aerodynamic surface. The composite material used in the
skin of a wing will depend on the design and requirements of the aircraft, but carbon
fibre reinforced polymer (CFRP) is a commonly used material for this application.

In addition to CFRP, other composite materials such as glass fibre reinforced polymer
(GFRP) or hybrid constructions of both CFRP and GFRP may also be used in the skin
of an aircraft wing. These materials offer similar properties to CFRP, but with
different cost and manufacturing considerations.

TAIL ASSEMBLY
The tail assembly of an aircraft includes the horizontal stabilizer, vertical stabilizer, and
rudder, which are used to control the pitch, yaw, and stability of the aircraft. Composite
materials are commonly used in the tail assembly of an aircraft due to their lightweight and
high-strength properties.
The horizontal stabilizer and elevator of an aircraft tail assembly may be made from
composite materials such as carbon fibre reinforced polymer (CFRP) or glass fibre reinforced
polymer (GFRP). These materials provide high strength and stiffness, while also allowing for
a lightweight structure that can improve the fuel efficiency of the aircraft.
The vertical stabilizer and rudder of an aircraft tail assembly may also be made from
composite materials, such as CFRP or hybrid constructions of both CFRP and GFRP. These
materials provide the necessary strength and stiffness for the tail assembly, while also
allowing for a lightweight structure that can improve the overall performance of the aircraft.
In addition to the structural components of the tail assembly, composite materials may also
be used in other parts, such as the fairings and access panels. These components can be
made from CFRP or GFRP to provide a lightweight and aerodynamic structure that can
improve the overall efficiency and performance of the aircraft.

ENGINE COMPONENTS
The use of composite materials in engine components of an aircraft is becoming more
common due to their excellent mechanical properties, including high strength, stiffness, and
fatigue resistance, as well as their ability to operate at high temperatures.
One common use of composites in engine components is in the fan blades and containment
systems of the aircraft engine. Composite materials such as carbon fibre reinforced polymer
(CFRP) or ceramic matrix composites (CMCs) are used to construct these components due to
their high strength-to-weight ratio, allowing for increased efficiency and fuel savings.
Additionally, CMCs are able to operate at higher temperatures than metals, making them an
ideal material for high-temperature applications.
Other engine components that may be made from composite materials include the nacelle
structure, inlet components, and exhaust components. Composites such as CFRP or GFRP
can be used in these components to reduce weight and improve fuel efficiency. CMCs are
also being used in exhaust components to improve durability and performance at high
temperatures.
However, there are some challenges to using composites in engine components. One major
challenge is the potential for damage due to foreign object debris (FOD) ingestion or bird
strikes, which can cause catastrophic failures. Additionally, composites may be more
susceptible to erosion and impact damage than metals. These challenges must be carefully
considered and addressed during the design and manufacturing of composite engine
components.
 COMPOSITES IN SPACE CRAFTS
The space shuttle was a complex and sophisticated spacecraft that used a wide range of
composite materials in various components. Some of the composites used in the making of
a space craft are mentioned below:

1. Carbon fibre reinforced polymer (CFRP) composites: CFRP composites are

extensively used in spacecraft construction, including in the structure of the
International Space Station (ISS). They are made of carbon fibres embedded in a
polymer matrix, usually epoxy. CFRP composites offer high strength-to-weight ratio
and excellent stiffness and durability, making them an ideal material for use in space.
They are used in various structural components of spacecraft, such as the payload
bay doors, solar panels, and antennas.
2. Ceramic matrix composites (CMCs): CMCs are used in spacecraft's heat shield
systems, such as those on the Mars Curiosity rover. CMCs are made of ceramic fibres
embedded in a ceramic matrix, which offer high thermal resistance and mechanical
strength at high temperatures. They are used in spacecraft's thermal protection
system, which protects the spacecraft from the extreme heat generated during entry
into the atmosphere of other planets.
3. Metal matrix composites (MMCs): MMCs are used in spacecraft's propulsion
systems, such as in rocket engines. MMCs are made of metal fibres embedded in a
metal matrix, offering high strength and stiffness, thermal stability, and corrosion
resistance. They are used in the manufacture of high-performance engine parts, such
as rocket nozzles and heat exchangers.
4. Fiberglass reinforced plastic (FRP) composites: FRP composites are used in the
construction of various non-structural components of spacecraft, such as insulation
and protective covers. They are made of fiberglass fibres embedded in a polymer
matrix, usually epoxy. FRP composites are lightweight, durable, and offer excellent
thermal and electrical insulation properties.
5. Titanium matrix composites (TMCs): TMCs are used in the manufacture of
spacecraft's structural components, such as trusses and frames. TMCs are made of
titanium fibres embedded in a titanium matrix, which offer high strength and
durability, as well as excellent resistance to fatigue and wear.
6. Kevlar composites: Kevlar composites are used in spacecraft's protective clothing,
such as spacesuits. Kevlar composites are made of Kevlar fibres embedded in a
polymer matrix, which offer excellent strength and durability. They are used in the
manufacture of protective clothing for astronauts, which protect them from the
extreme temperatures, radiation, and debris in space.
 7. Quartz-fibre composites: Quartz-fibre composites are used in spacecraft's windows,
such as those on the International Space Station. Quartz-fibre composites are made
of quartz fibres embedded in a polymer matrix, which offer high optical clarity and
are highly resistant to thermal shock and radiation damage, making them an ideal
material for use in space.
These are just a few examples of the many different composites used in spacecraft. Each
material is carefully selected and engineered to provide the necessary properties for its
specific application, helping to make spacecraft some of the most advanced and successful
machines in human history.

FUTURE OF COMPOSITE
MATERIALS IN AEROSPACE
INDUSTRY
The future of composite materials in the aerospace industry looks bright, as there is a
growing demand for lightweight and high-performance materials to improve fuel efficiency,
reduce emissions, and increase range and payload capabilities. Here are some potential
trends and developments to watch for in the future of composites in aerospace:
1. Advancements in composite materials: Research and development efforts are
underway to improve the performance and properties of composite materials, such
as developing new materials that are lighter, stronger, and more durable than
existing materials.
2. Hybrid materials: The use of hybrid materials, such as combining composites with
metals, ceramics, or other materials, is becoming increasingly popular as it allows
designers to optimize the properties of each material while reducing the overall
weight of the structure.
3. 3D printing: Additive manufacturing or 3D printing is revolutionizing the way
composite parts are manufactured, making it possible to produce complex
geometries that were previously impossible with traditional manufacturing methods.
4. Integrated structures: Designers are exploring the use of integrated structures,
where different parts of the aircraft are combined into a single component, reducing
weight and increasing efficiency.
5. Sustainable materials: The development of sustainable composite materials, such as
those made from bio-based sources, is gaining traction as the industry looks to
reduce its environmental impact.
 6. Increased automation: Automation is being used to improve the efficiency and
accuracy of manufacturing processes, reducing costs and lead times.

CONCLUSION
In conclusion, composite materials have become a key component of the aircraft industry,
delivering a unique combination of strength, durability, and low weight that makes them
perfect for a wide range of applications. The aerospace industry has been a driving force
behind the development of new composite materials and manufacturing techniques,
resulting in increasingly sophisticated and high-performance materials that are tailor-made
for specific aircraft applications.
The use of composite materials has allowed for significant weight savings, increased fuel
efficiency, and reduced maintenance costs, making them a crucial component of modern
aerospace design. They have been used extensively in primary structures like wings,
fuselages, and empennage, as well as secondary structures like fairings, nacelles, and
interior components.
Future developments in composite materials are anticipated to substantially improve the
effectiveness and performance of composite materials in aerospace applications. These
developments include the use of hybrid materials, 3D printing, integrated structures,
sustainable materials, and enhanced automation. Composite materials in aircraft have a
promising future, and it is anticipated that they will continue to be essential in determining
the direction of aviation.

REFERENCES
 "Spacecraft Materials and Mechanical Design" by Prasad S. Thenkabail, CRC Press,
2016.
 "Materials and Processes for Spacecraft and High Reliability Applications" by Barrie
D. Dunn, Elsevier, 2016.
 "Fiberglass Reinforced Plastics for Space Applications" by Tim Loftus, NASA Tech
Briefs, March 2005.
 “Advanced composite materials of the future in aerospace industry” by Maria
MRAZOVA