Engineering topics

Hanson, C. T.

Publications and source records attributed to Hanson, C. T..

3 records

NASA NTRS1997

Advanced Technology Composite Fuselage: Program Overview

The Advanced Technology Composite Aircraft Structures (ATCAS) program has studied transport fuselage structure with a large potential reduction in the total direct operating costs for wide-body commercial transports. The baseline fuselage section was divided into four 'quadrants', crown, keel, and sides, gaining the manufacturing cost advantage possible with larger panels. Key processes found to have savings potential include (1) skins laminated by automatic fiber placement, (2) braided frames using resin transfer molding, and (3) panel bond technology that minimized mechanical fastening. The cost and weight of the baseline fuselage barrel was updated to complete Phase B of the program. An assessment of the former, which included labor, material, and tooling costs, was performed with the help of design cost models. Crown, keel, and side quadrant cost distributions illustrate the importance of panel design configuration, area, and other structural details. Composite sandwich panel designs were found to have the greatest cost savings potential for most quadrants. Key technical findings are summarized as an introduction to the other contractor reports documenting Phase A and B work completed in functional areas. The current program status in resolving critical technical issues is also highlighted.

Ilcewicz, L. B.↗

NASA NTRS1997

Advanced Technology Composite Fuselage - Repair and Damage Assessment Supporting Maintenance

Under the NASA-sponsored contracts for Advanced Technology Composite Aircraft Structures (ATCAS) and Materials Development Omnibus Contract (MDOC), Boeing is studying the technologies associated with the application of composite materials to commercial transport fuselage structure. Included in the study is the incorporation of maintainability and repairability requirements of composite primary structure into the design. This contractor report describes activities performed to address maintenance issues in composite fuselage applications. A key aspect of the study was the development of a maintenance philosophy which included consideration of maintenance issues early in the design cycle, multiple repair options, and airline participation in design trades. Fuselage design evaluations considered trade-offs between structural weight, damage resistance/tolerance (repair frequency), and inspection burdens. Analysis methods were developed to assess structural residual strength in the presence of damage, and to evaluate repair design concepts. Repair designs were created with a focus on mechanically fastened concepts for skin/stringer structure and bonded concepts for sandwich structure. Both a large crown (skintstringer) and keel (sandwich) panel were repaired. A compression test of the keel panel indicated the demonstrated repairs recovered ultimate load capability. In conjunction with the design and manufacturing developments, inspection methods were investigated for their potential to evaluate damaged structure and verify the integrity of completed repairs.

Flynn, B. W.↗

NASA NTRS1997

Global Cost and Weight Evaluation of Fuselage Side Panel Design Concepts

This report documents preliminary design trades conducted under NASA contracts NAS1 18889 (Advanced Technology Composite Aircraft Structures, ATCAS) and NAS1-19349 (Task 3, Pathfinder Shell Design) for a subsonic wide body commercial aircraft fuselage side panel section utilizing composite materials. Included in this effort were (1) development of two complete design concepts, (2) generation of cost and weight estimates, (3) identification of technical issues and potential design enhancements, and (4) selection of a single design to be further developed. The first design concept featured an open-section stringer stiffened skin configuration while the second was based on honeycomb core sandwich construction. The trade study cost and weight results were generated from comprehensive assessment of each structural component comprising the fuselage side panel section from detail fabrication through airplane final assembly. Results were obtained in three phases: (1) for the baseline designs, (2) after global optimization of the designs, and (3) the results anticipated after detailed design optimization. A critical assessment of both designs was performed to determine the risk associated with each concept, that is the relative probability of achieving the cost and weight projections. Seven critical technical issues were identified as the first step towards side panel detailed design optimization.

Polland, D. R.↗