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Composite Design: Material Selection, Bonded Joints, and Sandwich Construction

Explore the fundamentals of composite design, including material selection, bonded joints, and honeycomb sandwich construction. Learn about failure modes, ply arrangement guidelines, and core properties. Take your composite design skills to the next level!

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Composite Design: Material Selection, Bonded Joints, and Sandwich Construction

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  1. Introduction Nothing can replace hands on shop experience as a prerequisite to good composite design. Without it, the design approach is based on intuition and theory alone, or at best, guided by manufacturing engineers. “A good design is unacceptable if it is unaffordable.” 1

  2. Material Selection: Tape -vs- Fabric 2

  3. Cocuring Assembly Examples 3

  4. Secondary Bonding Assembly Examples 4

  5. Corners 5

  6. Part Contour Limitations 6

  7. Surface Smoothness 7

  8. Ply Arrangement Guidelines 8

  9. Hole Drilling Guidelines 9

  10. Bonded Joint - Failure Modes 10

  11. Bonded Joint - Failure Modes (contd.) 11

  12. Highly Recommended 12

  13. Joint Types 13

  14. Affect of Adherened Stiffness on Loads in a Single Lap Joint 14

  15. Affect of Joint Length on Sheer Stress in a Single Lap Joint 15

  16. The fillet of adhesive plays an important role in joint strength. 16

  17. Finite Element Studies Stress Distributions -vs- Joint Type 17

  18. Ply Splices and Drop-Offs 18

  19. Maximum Taper Rate 19

  20. Mechanical Joint Failure Modes 20

  21. Mechanical Joint Design 21

  22. Fastener Selection for Corrosion Prevention 22

  23. Fastener Selection 23

  24. Honeycomb Sandwich Construction 24

  25. Failure Modes for Sandwich Beams Subjected to Loading Normal to the Faces 25

  26. Failures may also occur from a combination of two or more of these modes. Modes of Failure 26

  27. Honeycomb Sandwich: Edgeband and Attachments 27

  28. Examples of Sandwich Attachments 28

  29. Honeycomb Sandwich Edge Closure Concepts 29

  30. Core Costs 30

  31. Core Compressive Strengths 31

  32. Core Shear Strengths 32

  33. Core Shear Modulus 33

  34. Core type has negligible effect on beam stiffness. 34

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