Abstract: The types of composite components applied in aircrafts are different and complex, and the type, formation mechanism, and influence factor of manufacturing defects are also complex. These defects that often arise in autoclave molding are summarized, and the effect rules of complex structure on manufacturing defects are revealed on the basis of statistical analysis of a considerable amount of defect information obtained by nondestructive testing of composite components. Moreover, the formation mechanism is primarily analyzed. It is observed that delamination, pore, and void are the three main defect types in autoclave molding. In addition, the ratio of defect appearance is obviously influenced by the complexity of composite components. Geometric characteristics and the molding process for composite components have significant influence on the type and ratio of defects. The results are valuable for the controlling of manufacturing defects and the structure design of composite components.

Key words: composites, laminate, complex structure, autoclave molding, defect, delamination, void