MASTER TABLE: AIRCRAFT COMPOSITES, ADHESIVES, AND COMPOUNDS

  

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MASTER TABLE: AIRCRAFT COMPOSITES, ADHESIVES, AND COMPOUNDS

Category	Item	Typical Use in Aircraft
Structural Composites	Carbon Fiber Reinforced Polymer (CFRP)	Primary structure (fuselage, wings, empennage)
	Glass Fiber Reinforced Polymer (GFRP)	Radomes, fairings, secondary structures
	Aramid Fiber (Kevlar) Composites	Impact-resistant panels, ballistic protection
	Hybrid Composites (Carbon + Glass/Kevlar)	Balanced strength & impact resistance
	Thermoplastic Composites	Clips, brackets, interiors
	Resin Transfer Molded (RTM) Composites	Complex shaped structural parts
	Prepreg Composites	High-performance autoclave-cured structures
	Honeycomb Sandwich Panels (Nomex/Aluminum core)	Floors, control surfaces, panels
	Ceramic Matrix Composites (CMC)	Engine hot section (turbine shrouds, liners)
	Metal Matrix Composites (MMC)	High temperature structural components
Core Materials	Nomex Honeycomb	Lightweight structural core (interiors, control surfaces)
	Aluminum Honeycomb	High strength panels
	Foam Cores (PVC, PMI)	Sandwich panels, fairings
	Balsa Wood Core	Some legacy sandwich structures
Adhesives – Structural	Epoxy Adhesives	Primary bonding of composite structures
	Film Adhesives	Bonding skins to honeycomb cores
	Paste Adhesives	Gap filling structural bonding
	Cyanoacrylate (instant adhesive)	Minor repairs, temporary fixes
	Acrylic Structural Adhesives	Fast curing structural joints
	Polyurethane Adhesives	Flexible bonding applications
Adhesives – Specialized	High-temperature adhesives	Engine nacelles, hot zones
	Conductive adhesives	EMI grounding paths
	Fire-resistant adhesives	Cabin interiors
Sealants – Fuel & Fluid	Fuel Tank Sealant (Polysulfide)	Integral fuel tank sealing
	Wet installation sealant	Fastener sealing in fuel zones
	Thread sealants	Leak prevention in hydraulic/pneumatic systems
	Firewall sealants	Fire barrier sealing
Sealants – Environmental	Silicone sealants	High temperature zones, flexibility
	RTV sealants	General purpose sealing
	Weather sealants	Doors, windows
	Anti-corrosion sealants	Moisture protection
Coatings & Surface Treatments	Epoxy Primers	Corrosion protection
	Polyurethane Topcoats	Exterior paint systems
	Anti-erosion coatings	Leading edges
	Thermal barrier coatings (TBC)	Engine turbine components
	Dry film lubricants	Fasteners, sliding surfaces
	Conversion coatings (Alodine)	Aluminum corrosion protection
	Anodizing layers	Surface hardening and corrosion resistance
Potting & Encapsulation Compounds	Epoxy potting compounds	Electrical/electronic encapsulation
	Silicone potting compounds	Flexible electronic protection
	Polyurethane potting	Vibration-resistant encapsulation
Damping & Vibration Materials	Damping compounds	Reduce vibration/noise
	Acoustic insulation materials	Cabin noise reduction
Thermal Management Materials	Thermal interface materials (TIM)	Heat transfer in avionics
	Heat resistant resins	High temperature composite systems
Electrical Bonding Materials	Conductive sealants	Electrical bonding paths
	EMI shielding compounds	Electromagnetic protection
	Bonding pastes	Ground continuity
Repair Compounds	Composite repair resins	Field repair of composite parts
	Fillers (microballoons, epoxy fillers)	Surface finishing
	Edge fillers	Honeycomb edge sealing
	Abradable coatings	Compressor/turbine casing interfaces
Lubricants & Greases	Aircraft grease (MIL-spec)	Bearings, actuators
	Anti-seize compounds	Thread protection
	Solid lubricants (MoS₂)	High temperature lubrication
Special Purpose Compounds	Ice-phobic coatings	Anti-icing surfaces
	Lightning strike protection coatings	Composite surface protection
	Anti-static coatings	Static discharge control
	Fuel-resistant coatings	Fuel system durability

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Engineering Perspective (Real Aircraft Reality)

In aircraft like the Boeing 787 Dreamliner:

• ~50% of the structure is composite
• Thousands of bonded joints replace mechanical fasteners
• Fuel tank sealant alone runs into hundreds of kilograms
• Every fastener in fuel areas is wet-installed with sealant
• Composite repair kits are standard in maintenance hangars

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Practical Insight (From Shop Floor Experience)

If you have worked in overhaul or QC, you will clearly remember:

• Sealant application quality decides fuel leaks
• Adhesive bond failures are invisible but critical
• Improper curing → latent failures after months
• Composite damage often looks small outside but is deep inside

Unlike metal, composites don’t “bend and show.”
They fail quietly — and that’s what makes them both powerful and dangerous.

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