Understanding Aircraft Composite Construction: Basics of Materials and Techniques for the Non-Engineer

This book will introduce the non-engineer builder or technician to the general principles and techniques used in composite aircraft construction. The assumption is made that the reader is a complete beginner with no prior knowledge of composite materials, procedures or technology.

This book discusses three general areas:

1. Basic theory of strong materials, structures and composites.
2. Practical composite materials and structures in small aircraft.
3. Construction techniques used by the homebuilder and by prefabricated kit manufacturers.

Read this book if you are considering building either a manufactured kit or an aircraft design from plans using any technology. Composite aircraft structures are designed differently from those using earlier technologies such as wood or metal. You will understand those differences, including the advantages of building with composites.

Topics include:

• Strong Materials
• Forces in Structures
• Nature of Composite Materials
• Theory of Structural Sandwich
• Structural Fibers and Matrices
• Core Materials
• Joining Structures
• Solid Core Structures
• Moldless Tools and Techniques
• Moldless Core Layups
• Hollow Structures
• Making Molds
• Using Molds and Vacuum

Subtitle- "Basics of Materials and Techniques for the Non-engineer"

This book explains, in plain language, without difficult mathematics, how and why composite materials work and how this family of materials achieves high mechanical performance, particularly in small aircraft.

Three general areas are discussed:

(1) BASIC THEORY OF STRONG MATERIALS, extended to the special case of composite materials, and including simple beams, the nature of shear forces, and the derivation of the simple sandwich structure. Failure modes of loaded structures. This section explains why sandwich structures are efficient and why they are so widely used in aircraft.

(2) MATERIALS AND STRUCTURES currently used in small aircraft. Matrix systems currently available. Variations of the sandwich principle to make more complex solid-core shapes like wings. Hybrid structures, including imbedded spars. Hollow structures made from sandwich skins.

(3) CONSTRUCTION TECHNIQUES which are practical for the homebuilder. The widely-used "Rutan" moldless methods (VariEze, Dragonfly, etc.) are described in detail, including simple finishing techniques. Plug and mold-making, including large molds applicable to wing skins and fuselage sections. Making precision curved sandwich surfaces using simple vacuum bagging techniques which are not yet widely used in home shops, but which can use ordinary hardware store materials.

The target reader is a builder who is considering an aircraft project but may not have chosen the technology (tube and fabric, wood, aluminum) and needs to learn enough about the principles of composite construction to make an informed choice. This book will be of particular interest to the builder who is considering one of the popular prefab kits like the Glasair, Lancair, or KIS, where most of the structure consists of large, precision-molded sandwich forms. While not a design manual, the book will be of special interest to a builder who wishes to develop his own design and is prepared to do the necessary testing of prototype structures.