You have been asked to manufacture a wiring junction box for connecting electrical wires in a fighter aircraft. The box sits under the pilot's seat and is part of the seat ejection system. Sufficient forces are exerted on the box that it must be made of a composite material using intermediate to long fibers. What fiber, matrix, and manufacturing method would you use for this part, and why?
What will be an ideal response?
Several materials could be chosen but, because of its good electrical and heat insulative capability and its non-flammable nature, phenolic seems to be the appropriate resin. The fibers need to be strong, stiff, and tough enough to withstand the ejection impact. Therefore, aramid is a good choice for the fibers. The manufacturing process could be either compression molding or RTM, probably depending upon whether the fibers need to be longer than those that could conveniently be used in compression molding.
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