Combining two or more materials with different properties creates composite materials, or composites. The combined materials create a superior material; stronger, lighter, or more flexible than its components.
Aerospace composites refer specifically to composite materials that are used in aircraft, spacecraft, and satellites. The experts over at Axiom Materials explain that some common aerospace composites combine carbon fibers and epoxy resins. Carbon fiber provides strength and stiffness while the epoxy resin holds the carbon fibers together and gives the material its shape.
Why Use Composites in Aerospace?
Aerospace designers choose composites for many reasons. A big one is that composites can be extraordinarily strong and very light. Using lighter materials helps planes, rockets, and satellites save fuel by weighing less. Composites can also handle stresses like twisting and heat better than metals. Their strength lets engineers make parts thinner and simpler. Simpler part designs also save weight.
How Aerospace Composites Are Made
Laying Out the Pieces
The first step is to prepare the separate pieces that will make up the composite material. This often means grouping tiny carbon fiber strands into a sheet. The fibers line up parallel to each other for maximum strength. Later steps will bind them together.
Prepreg Composite Materials
Aerospace carbon fiber sheets often arrive at factories already soaked with epoxy resin. This is called “prepreg” composite material. The resin soaks or wets all the fibers to stick them together. Prepreg sheets have the right amount of resin evenly spread, which helps to avoid weak or heavy spots when parts cure.
Shaping and Curing Parts
Next, workers carefully layer prepreg sheets based on the needed part shape. The layers align in different orientations. This makes the final part resist bending and twisting in all directions. Workers use vacuum bags and ovens to heat or autoclave the parts. The heat causes the epoxy resin to harden fully. This changes the layers of ingredient materials into a solid final piece.
Advanced Manufacturing Methods
Printed Parts
One newer method is printing parts from composite material ink. Printers work from digital part designs to lay down material only where needed. This technique promises lighter weight and cheaper costs than classic layering methods. Nevertheless, printed composite parts require extra structural support during printing and curing.
Out-of-Autoclave Curing
Traditional oven and vacuum bag curing uses high heat and pressure, which is called autoclave curing. New out-of-autoclave processes now promise similar results without huge ovens. This can lower costs and energy use. It also suits printing better since prints often need gentler, uniform curing conditions.
Continuous Production Processes
Classic methods combine layers by hand. Newer automated processes assemble and cure components constantly, which resembles a factory production line. It provides a smooth flow from raw ingredients to completed parts without pauses. Aerospace firms now study weaving carbon fiber pre-forms on looms or braiding them via robots.
Repairing Composite Parts
An advantage of composites is only damaged sections need fixing. Workers simply cut out and replace broken areas. Technicians can even patch holes with composite materials using special heat tools. Being able to fix parts extends the lifespan of planes and spacecraft, which saves money and resources.
Conclusion
Aerospace composite materials continue to revolutionize flight and space exploration. As manufacturing techniques advance, these materials become stronger, lighter, and more cost-effective to produce. While challenges remain in optimizing production speeds and reducing costs, the advantages of composite materials ensure their growing role in aerospace applications. From commercial aircraft to deep space missions, composites will remain at the forefront of aerospace innovation, enabling the next generation of lighter, more efficient, and more capable aerospace vehicles.
