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Chapter One APPLICATIONS Although the two industries are so vastly different, lessons can be learned from aircraft development programs that are applicable to marine structures. Material and process development, design methodologies, qualification programs and long-term performance are some of the fields where the marine designer can adapt the experience that the aerospace industry has developed. New aircraft utilize what would be considered high performance composites in marine terms. These include carbon, boron and aramid fibers combined with epoxy resins. Such materials have replaced fiberglass reinforcements, which are still the backbone of the marine industry. However, structural integrity, producibility and performance at elevated temperatures are some concerns common to both industries. Examples of specific aerospace composites development programs are provided to illustrate the direction of this industry. Business and Commercial Lear Fan 2100 As one of the first aircraft conceived and engineered as a composites craft, the Lear Fan uses approximately 1880 pounds of carbon, glass and aramid fiber material. In addition to composite elements that are common to other aircraft, such as doors, control surfaces, fairings and wing boxes, the Lear Fan has an all-composite body and propeller blades. Beech Starship The Starship is the first all-composite airplane to receive FAA certification. Approximately 3000 pounds of composites are used on each aircraft. Boeing The Boeing 757 and 767 employ about 3000 pounds each of composites for doors and control surfaces. The 767 rudder at 36 feet is the largest commercial component in service. The 737- 300 uses approximately 1500 pounds of composites, which represents about 3% of the overall structural weight. Composites are widely used in aircraft interiors to create luggage compartments, sidewalls, floors, ceilings, galleys, cargo liners and bulkheads. Fiberglass with epoxy or phenolic resin utilizing honeycomb sandwich construction gives the designer freedom to create aesthetically pleasing structures while meeting flammability and impact resistance requirements. Airbus In 1979, a pilot project was started to manufacture carbon fiber fin box assemblies for the A300/A310 aircraft. A highly mechanized production process was established to determine if high material cost could be offset by increased manufacturing efficiency. Although material costs were 35% greater than a comparable aluminum structure, total manufacturing costs were lowered 65 to 85%. Robotic assemblies were developed to handle and process materials in an optimal and repeatable fashion. Military Advanced Tactical Fighter (ATF) Advanced composites enable the ATF to meet improved performance requirements such as reduced drag, low radar observability and increased resistance to temperatures generated at 58PDF Image | Marine Componsites
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