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The Comparison of Composite Aircraft Field Repair Method (CAFRM) with Traditional Aircraft Repair Technologies

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The Comparison of Composite Aircraft Field Repair Method (CAFRM) with Traditional Aircraft Repair Technologies Purdue University Purdue e-Pubs Open Access Dissertations Theses and Dissertations Fall 2013 The ompC arison of Composite Aircraft ieldF Repair Method (CAFRM) with Traditional Aircraft Repair Technologies Peng Hao Wang Purdue University Follow this and additional works at: https://docs.lib.purdue.edu/open_access_dissertations Part of the Aerospace Engineering Commons, and the Materials Science and Engineering Commons Recommended Citation Wang, Peng Hao, "The ompC arison of Composite Aircraft ieF ld Repair Method (CAFRM) with Traditional Aircraft Repair Technologies" (2013). Open Access Dissertations. 30. https://docs.lib.purdue.edu/open_access_dissertations/30 This document has been made available through Purdue e-Pubs, a service of the Purdue University Libraries. Please contact [email protected] for additional information. Graduate School ETD Form 9 (Revised 12/07) PURDUE UNIVERSITY GRADUATE SCHOOL Thesis/Dissertation Acceptance This is to certify that the thesis/dissertation prepared By Peng Hao Wang Entitled The Comparison of Composite Aircraft Field Repair Method (CAFRM) with Traditional Aircraft Repair Technologies Doctor of Philosophy For the degree of Is approved by the final examining committee: Ronald Sterkenburg Chair Richard O. Fanjoy Chien-Tsung Lu Jeffrey P. Youngblood To the best of my knowledge and as understood by the student in the Research Integrity and Copyright Disclaimer (Graduate School Form 20) , this thesis/dissertation adheres to the provisions of Purdue University’s “Policy on Integrity in Research” and the use of copyrighted material. Approved by Major Professor(s): ___________________Ronald Sterkenburg _________________ ____________________________________ Approved by: James L. Mohler 11/20/2013 Head of the Graduate Program Date 1 THE COMPARISON OF COMPOSITE AIRCRAFT FIELD REPAIR METHOD (CAFRM) WITH TRADITIONAL AIRCRAFT REPAIR TECHNOLOGIES A Dissertation Submitted to the Faculty of Purdue University by Peng Hao Wang In Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy December 2013 Purdue University West Lafayette, Indiana ii To my family, for all the countless support, encouragement, and patience they have given me throughout the years. To my beautiful wife Wen Yu, I would not have made it through without your constant encouragement and support. Thank you so much for taking care of things at home while I am busy with work and most of all, thank you so much for giving me our son Ayrton. iii ACKNOWLEDGEMENTS The past 10 years have been a very memorable and important learning experience for me. I would like to thank all my professors and colleagues for the wonderful experience and lessons learnt. These experiences and life lessons will help guide me into the upcoming future. Dr. Ronald Sterkenburg, thank you so much for all the opportunities you have given me throughout my college career. It is an understatement to say that my life would be completely different without all your guidance and support. You have been a wonderful professor, mentor, life counselor, and friend. All the experiences and memories while working with you will be deeply cherished and important for the years to come. I would also like to thank my committee members, Dr. Richard Fanjoy, Dr. Chien-Tsung Lu, and Dr. Jeffrey Youngblood for their time and guidance to help me complete my graduate studies. iv TABLE OF CONTENTS Page LIST OF TABLES .................................................................................................vi LIST OF FIGURES .............................................................................................. vii ABSTRACT ......................................................................................................... xii CHAPTER 1. INTRODUCTION ........................................................................ 1 1.1 Introduction .................................................................................... 1 1.2 Background of the Study ............................................................... 3 1.3 Statement of the Problem .............................................................. 6 1.4 Purpose and Objectives of the Study ............................................ 7 1.5 Research Question ........................................................................ 7 1.6 Hypotheses ................................................................................... 8 1.7 Significance of the Study ............................................................... 9 1.8 Assumptions of the Study .............................................................. 9 1.9 Limitations of the Study ............................................................... 10 1.10 Delimitations of the Study ............................................................ 10 CHAPTER 2. REVIEW OF THE LITERATURE .............................................. 12 2.1 History of Composite Materials .................................................... 12 2.2 Fabrication Methods .................................................................... 13 2.3 Testing Methods .......................................................................... 20 2.4 Composite Aircraft Field Repair Method (CAFRM) ...................... 29 2.5 Review of the Literature Summary .............................................. 33 CHAPTER 3. METHODOLOGY ..................................................................... 35 3.1 Type of Research Study .............................................................. 35 3.2 Research Question ...................................................................... 40 3.3 Hypotheses ................................................................................. 40 3.4 Reliability and Validity .................................................................. 42 3.5 Sampling Plan ............................................................................. 48 3.6 Specimens ................................................................................... 53 v Page 3.6.1 Preimpregnated (Prepreg) Fabric Cured in an Autoclave ...... 53 3.6.2 Double Vacuum De-Bulk (DVD) Method ............................... 59 3.6.3 Composite Aircraft Field Repair Method (CAFRM)................ 70 3.6.4 Specimen Partitioning ........................................................... 79 3.6.5 Specimen Preparation ........................................................... 80 3.7 Testing Procedures ................................................................... 105 3.7.1 Microscopy Testing Procedures .......................................... 105 3.7.2 Acid Digesting Testing Procedures ..................................... 107 3.7.3 Short Beam Shear Testing Procedures ............................... 111 3.7.4 Mode I Fracture Testing Procedures ................................... 113 3.8 Statistical Analysis ..................................................................... 115 3.9 Methodology Summary .............................................................. 116 CHAPTER 4. RESEARCH FINDINGS ......................................................... 118 4.1 Microscopy Test ........................................................................ 118 4.2 Acid Digestion Test.................................................................... 122 4.3 Short Beam Shear Test ............................................................. 126 4.4 Mode I Fracture Test ................................................................. 131 CHAPTER 5. CONCLUSIONS AND RECOMMENDATIONS ...................... 136 5.1 Hypotheses ............................................................................... 136 5.2 Microscopy Test ........................................................................ 138 5.3 Acid Digestion Test.................................................................... 139 5.4 Short Beam Shear Test ............................................................. 140 5.5 Mode I Fracture Test ................................................................. 141 5.6 Conclusions ............................................................................... 142 5.7 Recommendations for Future Research .................................... 143 LIST OF REFERENCES .................................................................................. 144 VITA ................................................................................................................. 151 vi LIST OF TABLES Table .............................................................................................................. Page Table 3.1 Specimen Numbers for Each Test ...................................................... 53 Table 4.1 Void Percentages from Microscopy Test .......................................... 120 Table 4.2 One-Way ANOVA for Void Percentages ........................................... 122 Table 4.3 Fiber Volume Fraction from Acid Digestion Test .............................. 124 Table 4.4 One-Way ANOVA for Fiber Volume Fraction .................................... 126 Table 4.5 Short Beam Shear Test Load Data ................................................... 130 Table 4.6 One-Way ANOVA for Short Beam Shear Test ................................. 131 Table 4.7 Mode I Fracture Toughness .............................................................. 134 Table 4.8 One-Way ANOVA for Mode I Fracture Test ...................................... 135 vii LIST OF FIGURES Figure ............................................................................................................
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