Advantages of Composites

Composite construction offers several advantages over metal, wood, or fabric, with its lighter weight being the most frequently cited. Lighter weight is not always automatic. It must be remembered that building an aircraft structure out of composites does not guarantee it will be lighter, it depends on the structure, as well as the type of composite being used.

A more important advantage is that a very smooth, compound curved, aerodynamic structure made from composites reduces drag. This is the main reason sailplane designers switched from metal and wood to composites in the 1960s. In aircraft, the use of composites reduces drag for the Cirrus and Columbia line of production aircraft, leading to their high performance despite their fixed landing gear. Composites also help mask the radar signature of “stealth” aircraft designs, such as the B-2 and the F-22. Today, composites can be found in aircraft as varied as gliders to most new helicopters.

Lack of corrosion is a third advantage of composites. Boeing is designing the 787, with its all-composite fuselage, to have both a higher pressure differential and higher humidity in the cabin than previous airliners. Engineers are no longer as concerned about corrosion from moisture condensation on the hidden areas of the fuselage skins, such as behind insulation blankets. This should lead to lower long-term maintenance costs for the airlines.

Another advantage of composites is their good performance in a flexing environment, such as in helicopter rotor blades. Composites do not suffer from metal fatigue and crack growth as do metals. While it takes careful engineering, composite rotor blades can have considerably higher design lives than metal blades, and most new large helicopter designs have all composite blades, and in many cases, composite rotor hubs.

Composite Materials in Aircraft

Composite materials are fiber-reinforced matrix systems. The matrix is the “glue” used to hold the fibers together and, when cured, gives the part its shape, but the fibers carry most of the load. There are many different types of fibers and matrix systems.

In aircraft, the most common matrix is epoxy resin, which is a type of thermosetting plastic. Compared to other choices such as polyester resin, epoxy is stronger and has good high-temperature properties. There are many different types of epoxies available, with a wide range of structural properties, cure times and temperatures, and costs.

The most common reinforcing fibers used in aircraft construction are fiberglass and carbon fiber. Fiberglass has good tensile and compressive strength, good impact resistance, is easy to work with, and is relatively inexpensive and readily available. Its main disadvantage is that it is relatively heavy, and it is difficult to make a fiberglass load-carrying structure lighter than a well designed equivalent aluminum structure.

Carbon fiber is generally stronger in tensile and compressive strength than fiberglass, and has much higher bending stiffness. It is also considerably lighter than fiberglass. However, it is relatively poor in impact resistance; the fibers are brittle and tend to shatter under sharp impact. This can be greatly improved with a “toughened” epoxy resin system, as used in the Boeing 787 horizontal and vertical stabilizers. Carbon fiber is more expensive than fiberglass, but the price has dropped due to innovations driven by the B-2 program in the 1980s, and Boeing 777 work in the 1990s. Very well-designed carbon fiber structures can be significantly lighter than an equivalent aluminum structure, sometimes by 30 percent or so.

Types of Aircraft Construction

The construction of aircraft fuselages evolved from the early wood truss structural arrangements to monocoque shell structures to the current semimonocoque shell structures.

Truss Structure

The main drawback of truss structure is its lack of a streamlined shape. In this construction method, lengths of tubing, called longerons, are welded in place to form a well-braced framework. Vertical and horizontal struts are welded to the longerons and give the structure a square or rectangular shape when viewed from the end. Additional struts are needed to resist stress that can come from any direction. Stringers and bulkheads, or formers, are added to shape the fuselage and support the covering.

As technology progressed, aircraft designers began to enclose the truss members to streamline the airplane and improve performance. This was originally accomplished with cloth fabric, which eventually gave way to lightweight metals such as aluminum. In some cases, the outside skin can support all or a major portion of the flight loads. Most modern aircraft use a form of this stressed skin structure known as monocoque or semimonocoque construction. [Figure 2-14]

Monocoque

Monocoque construction uses stressed skin to support almost all loads much like an aluminum beverage can. Although very strong, monocoque construction is not highly tolerant to deformation of the surface. For example, an aluminum beverage can supports considerable forces at the ends of the can, but if the side of the can is deformed slightly while supporting a load, it collapses easily.

Because most twisting and bending stresses are carried by the external skin rather than by an open framework, the need for internal bracing was eliminated or reduced, saving weight and maximizing space. One of the notable and innovative methods for using monocoque construction was employed by Jack Northrop. In 1918, he devised a new way to construct a monocoque fuselage used for the Lockheed S-1 Racer. The technique utilized two molded plywood half-shells that were glued together around wooden hoops or stringers. To  construct the half shells, rather than gluing many strips of plywood over a form, three large sets of spruce strips were soaked with glue and laid in a semi-circular concrete mold that looked like a bathtub. Then, under a tightly clamped lid, a rubber balloon was inflated in the cavity to press the plywood against the mold. Twenty-four hours later, the smooth half-shell was ready to be joined to another to create the fuselage. The two halves were each less than a quarter inch thick. Although employed in the early aviation period, monocoque construction would not reemerge for several decades due to the complexities involved. Every day examples of monocoque construction can be found in automobile manufacturing where the unibody is considered standard in manufacturing.

Semimonocoque

Semimonocoque construction, partial or one-half, uses a substructure to which the airplane’s skin is attached. The substructure, which consists of bulkheads and/or formers of various sizes and stringers, reinforces the stressed skin by taking some of the bending stress from the fuselage. The main section of the fuselage also includes wing attachment points and a firewall. On single-engine airplanes, the engine is usually attached to the front of the fuselage. There is a fireproof partition between the rear of the engine and the flight deck or cabin to protect the pilot and passengers from accidental engine fires. This partition is called a firewall and is usually made of heat-resistant material such as stainless steel. However, a new emerging process of construction is the integration of composites or aircraft made entirely of composites.

Composite Construction
History

The use of composites in aircraft construction can be dated to World War II aircraft when soft fiberglass insulation was used in B-29 fuselages. By the late 1950s, European high performance sailplane manufacturers were using fiberglass as primary structures. In 1965, the FAA type certified the first all-fiberglass aircraft in the normal category, a Swiss sailplane called a Diamant HBV. Four years later, the FAA certified a four-seat single-engine Windecker Eagle in the normal category. By 2005, over 35 percent of new aircraft were constructed of composite materials.

Composite is a broad term and can mean materials such as fiberglass, carbon fiber cloth, Kevlar© cloth, and mixtures of all of the above. Composite construction offers two advantages: extremely smooth skins and the ability to easily form complex curved or streamlined structures. [Figure 2-15]

Subcomponents

The subcomponents of an airplane include the airframe, electrical system, flight controls, and brakes. The airframe is the basic structure of an aircraft and is designed to withstand all aerodynamic forces, as well as the stresses imposed by the weight of the fuel, crew, and payload.

The primary function of an aircraft electrical system is to generate, regulate, and distribute electrical power throughout the aircraft. There are several different power sources on aircraft to power the aircraft electrical systems. These power sources include: engine-driven alternating current (AC) generators, auxiliary power units (APUs), and external power. The aircraft’s electrical power system is used to operate the flight instruments, essential systems such as anti-icing, etc., and passenger services, such as cabin lighting.
The flight controls are the devices and systems which govern the attitude of an aircraft and, as a result, the flightpath followed by the aircraft. In the case of many conventional airplanes, the primary flight controls utilize hinged, trailing-edge surfaces called elevators for pitch, ailerons for roll, and the rudder for yaw. These surfaces are operated by the pilot in the flight deck or by an automatic pilot.

Airplane brakes consist of multiple pads (called caliper pads) that are hydraulically squeezed toward each other with a rotating disk (called a rotor) between them. The pads place pressure on the rotor which is turning with the wheels. As a result of the increased friction on the rotor, the wheels inherently slow down and stop turning. The disks and brake pads are made either from steel, like those in a car, or from a carbon material that weighs less and can absorb more energy. Because airplane brakes are used principally during landings and must absorb enormous amounts of energy, their life is measured in landings rather than miles.

The Powerplant

The powerplant usually includes both the engine and the propeller. The primary function of the engine is to provide the power to turn the propeller. It also generates electrical power, provides a vacuum source for some flight instruments, and in most single-engine airplanes, provides a source of heat for the pilot and passengers. [Figure 2-13] The engine is covered by a cowling, or a nacelle, which are both types of covered housings. The purpose of the cowling or nacelle is to streamline the flow of air around the engine and to help cool the engine by ducting air around the cylinders.

The propeller, mounted on the front of the engine, translates the rotating force of the engine into thrust, a forward acting force that helps move the airplane through the air. The propeller may also be mounted on the rear of the engine as in a pusher-type aircraft. A propeller is a rotating airfoil that produces thrust through aerodynamic action. A low pressure area is formed at the back of the propeller’s airfoil, and high pressure is produced at the face of the propeller, similar to the way lift is generated by an airfoil used as a lifting surface or wing. This pressure differential pulls air through the propeller, which in turn pulls the airplane forward.

There are two significant factors involved in the design of a propeller which impact its effectiveness. The angle of a propeller blade, as measured against the hub of the propeller, keeps the angle of attack relatively constant along the span of the propeller blade, reducing or eliminating the possibility of a stall. The pitch is defined as the distance a propeller would travel in one revolution if it were turning in a solid. These two factors combine to allow a measurement of the propeller’s efficiency. Propellers are usually matched to a specific aircraft/powerplant combination to achieve the best efficiency at a particular power setting, and they pull or push depending on how the engine is mounted.

Landing Gear

The landing gear is the principal support of the airplane when parked, taxiing, taking off, or landing. The most common type of landing gear consists of wheels, but airplanes can also be equipped with floats for water operations, or skis for landing on snow. [Figure 2-12]

The landing gear consists of three wheels—two main wheels and a third wheel positioned either at the front or rear of the airplane. Landing gear with a rear mounted wheel is called conventional landing gear.
Airplanes with conventional landing gear are sometimes referred to as tailwheel airplanes. When the third wheel is located on the nose, it is called a nosewheel, and the design is referred to as a tricycle gear. A steerable nosewheel or tailwheel permits the airplane to be controlled throughout all operations while on the ground. Most aircraft are steered by moving the rudder pedals, whether nosewheel or tailwheel. Additionally, some aircraft are steered by differential braking.

Empennage

The empennage includes the entire tail group and consists of fixed surfaces such as the vertical stabilizer and the horizontal stabilizer. The movable surfaces include the rudder, the elevator, and one or more trim tabs. [Figure 2-10]

The rudder is attached to the back of the vertical stabilizer. During flight, it is used to move the airplane’s nose left and right. The elevator, which is attached to the back of the horizontal stabilizer, is used to move the nose of the airplane up and down during flight. Trim tabs are small, movable portions of the trailing edge of the control surface. These movable trim tabs, which are controlled from the flight deck, reduce control pressures. Trim tabs may be installed on the ailerons, the rudder, and/or the elevator.

A second type of empennage design does not require an elevator. Instead, it incorporates a one-piece horizontal stabilizer that pivots from a central hinge point. This type of design is called a stabilator, and is moved using the control wheel, just as the elevator is moved. For example, when a pilot pulls back on the control wheel, the stabilator pivots so the trailing edge moves up. This increases the aerodynamic tail load and causes the nose of the airplane to move up. Stabilators have an antiservo tab extending across their trailing edge. [Figure 2-11]

The antiservo tab moves in the same direction as the trailing edge of the stabilator and helps make the stabilator less sensitive. The antiservo tab also functions as a trim tab to relieve control pressures and helps maintain the stabilator in the desired position.

Major Components

Although airplanes are designed for a variety of purposes, most of them have the same major components. [Figure 2-4] The overall characteristics are largely determined by the original design objectives. Most airplane structures include a fuselage, wings, an empennage, landing gear, and a powerplant.

Fuselage

The fuselage is the central body of an airplane and is designed to accommodate the crew, passengers, and cargo. It also provides the structural connection for the wings and tail assembly. Older types of aircraft design utilized an open truss structure constructed of wood, steel, or aluminum tubing. [Figure 2-5] The most popular types of fuselage structures used in today’s aircraft are the monocoque (French for “single shell”) and semimonocoque. These structure types are discussed in more detail under aircraft construction later in the chapter.

Wings

The wings are airfoils attached to each side of the fuselage and are the main lifting surfaces that support the airplane in flight. There are numerous wing designs, sizes, and shapes used by the various manufacturers. Each fulfills a certain need with respect to the expected performance for the particular airplane. How the wing produces lift is explained in Chapter 4, Aerodynamics of Flight.

Wings may be attached at the top, middle, or lower portion of the fuselage. These designs are referred to as high-, mid-, and low-wing, respectively. The number of wings can also vary. Airplanes with a single set of wings are referred to as monoplanes, while those with two sets are called biplanes. [Figure 2-6]

Many high-wing airplanes have external braces, or wing struts, which transmit the flight and landing loads through the struts to the main fuselage structure. Since the wing struts are usually attached approximately halfway out on the wing, this type of wing structure is called semi-cantilever. A few high-wing and most low-wing airplanes have a full cantilever wing designed to carry the loads without external struts.
The principal structural parts of the wing are spars, ribs, and stringers. [Figure 2-7] These are reinforced by trusses, I-beams, tubing, or other devices, including the skin. The wing ribs determine the shape and thickness of the wing (airfoil). In most modern airplanes, the fuel tanks either are an integral part of the wing’s structure, or consist of flexible containers mounted inside of the wing.

Attached to the rear or trailing edges of the wings are two types of control surfaces referred to as ailerons and flaps. Ailerons extend from about the midpoint of each wing outward toward the tip, and move in opposite directions to create aerodynamic forces that cause the airplane to roll. Flaps extend outward from the fuselage to near the midpoint of each wing. The flaps are normally flush with the wing’s surface during cruising flight. When extended, the flaps move simultaneously downward to increase the lifting force of the wing for takeoffs and landings. [Figure 2-8]

Alternate Types of Wings

With the Federal Aviation Administration’s (FAA) recent addition of the LSA category, various methods are employed to control flight and to produce lift. These methods are discussed in Chapter 4, Aerodynamics of Flight, which provides information on the effect controls have on lifting surfaces from traditional wings to wings that use both flexing (due to billowing) and shifting (through the change of the aircraft’s CG). Handbooks specific to each category of LSA are available for the interested pilot. LSA illustrate various lifting surfaces and control methods. For example, the wing of the weight-shift control aircraft is highly swept, and the shifting of weight to provide controlled flight. [Figure 2-9]

Lift and Basic Aerodynamics

In order to understand the operation of the major components and subcomponents of an aircraft, it is important to understand basic aerodynamic concepts. This chapter briefly introduces aerodynamics; a more detailed explanation can be found in Chapter 4, Aerodynamics of Flight.
Four forces act upon an aircraft in relation to straight-and-level, unaccelerated flight. These forces are thrust, lift, weight, and drag. [Figure 2-1]

Thrust is the forward force produced by the powerplant/propeller. It opposes or overcomes the force of drag. As a general rule, it is said to act parallel to the longitudinal axis. This is not always the case as explained later.

Drag is a rearward, retarding force, and is caused by disruption of airflow by the wing, fuselage, and other protruding objects. Drag opposes thrust, and acts rearward parallel to the relative wind.

Weight is the combined load of the airplane itself, the crew, the fuel, and the cargo or baggage. Weight pulls the airplane downward because of the force of gravity. It opposes lift, and acts vertically downward through the airplane’s center of gravity (CG).
Lift opposes the downward force of weight, is produced by the dynamic effect of the air acting on the wing, and acts perpendicular to the flightpath through the wing’s center of lift.

An aircraft moves in three dimensions and is controlled by moving it about one or more of its axes. The longitudinal or roll axis extends through the aircraft from nose to tail, with the line passing through the CG. The lateral or pitch axis extends across the aircraft on a line through the wing tips, again passing through the CG. The vertical, or yaw, axis passes through the aircraft vertically, intersecting the CG. All control movements cause the aircraft to move around one or more of these axes, and allows for the control of the airplane in flight. [Figure 2-2]

One of the most significant components of aircraft design is CG. It is the specific point where the mass or weight of an aircraft may be said to center; that is, a point around which, if the aircraft could be suspended or balanced, the aircraft would remain relatively level. The position of the CG of an aircraft determines the stability of the aircraft in flight. As the CG moves rearward (towards the tail) the aircraft becomes more and more dynamically unstable. In aircraft with fuel tanks situated in front of the CG, it is important that the CG is set with the fuel tank empty. Otherwise, as the fuel is used, the aircraft becomes unstable. [Figure 2-3] The CG is computed during initial design and construction, and is further affected by the installation of onboard equipment, aircraft loading, and other factors.