Performance Plastic Materials For Aerospace

Plastics cover a broad field of organic synthetic resin and may be divided into two main classifications – aerospace thermoplastics _ and aerospace thermosetting plastics. Thermoplastics may be softened by heat and can be dissolved in various organic solvents.

Makrolon Polycarbonate Sheet

Aerospace Thermoplastics

Thermoplastics may be softened by heat and can be dissolved in various organic solvents. Two kinds of transparent thermoplastic materials are commonly employed in windows, canopies, etc. These are known as acrylic plastics and cellulose acetate plastics. Cellulose acetate was used in the past but since it is dimensionally unstable and turns yellow after it has been installed for a time, it has just about passed from the scene and is not considered an acceptable substitute for acrylic.

Aerospace Thermosetting Plastics

Thermosetting plastics do not soften appreciably under heat but may char and blister at temperatures of 240 to 260 ‘C (400 to 500 °F). Most of the molded products of synthetic resin composition, such as phenolic, urea-formaldehyde, and melamine formaldehyde resins, belong to the thermosetting group. Once the plastic becomes hard, additional heat will not change it back into a liquid as it would with a thermoplastic.

Storage and handling

Because transparent thermoplastic sheets soften and deform when they are heated, they must be where the temperature will never be excessive.

Aerospace thermoforming

Transparent acrylic plastics get soft and pliable when they are heated to their forming temperatures and can be formed to almost any shape. When they cool, they retain the shape to which they were formed. Acrylic plastic may be cold-bent into a single curvature if the material is thin and the bending radius is at least 180 times the thickness of the sheet. Cold bending beyond these limits will impose so much stress on the surface of the plastic that tiny fissures or cracks, called crazing, will form.

Forming methods

Simple Curve Forming. Heat the plastic material to the recommended temperature, remove it from the heat source, and carefully drape it over the prepared form. Carefully press the hot plastic to the form and either hold or clamp the sheet in place until it cools. This process may take from ten minutes to one-half hour. Do not force-cool it.

Compound-Curve Forming

This type of forming is normally used for such parts as canopies or complex wingtip light covers, and it requires a great deal of specialized equipment. There are four commonly used methods, each having its advantages and disadvantages.

Aerospace Vacuum Forming Without Forms. Many aircraft canopies are formed by this method. In this process a clamp with an opening of the desired shape is placed over a vacuum box and the heated sheet of plastic is clamped in place. When the air in the box is evacuated, the outside air pressure will force the hot plastic through the opening and form the concave canopy. It is the surface tension of the plastic that shapes the canopy.

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