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At least 199 records · Page 11

Assessment of state-of-the-art of in-service inspection methods for graphite epoxy composite structures on commercial transport aircraft

A survey was conducted to determine current in-service inspection practices for all types of aircraft structure and particularly for advanced composite structures. The survey consisted of written questionnaires to commercial airlines, visits to airlines, aircraft manufacturers, and government agencies, and a literature search. Details of the survey including visits, questions asked, a bibliography of reviewed literature and details of the results are reported. From the results, a current in-service inspection baseline and a preliminary inspection program for advanced composite structures is documented as appendices to the report.

Phelps, M. L.↗

Comparison of Requirements for Composite Structures for Aircraft and Space Applications

In this report, the aircraft and space vehicle requirements for composite structures are compared. It is a valuable exercise to study composite structural design approaches used in the airframe industry and to adopt methodology that is applicable for space vehicles. The missions, environments, analysis methods, analysis validation approaches, testing programs, build quantities, inspection, and maintenance procedures used by the airframe industry, in general, are not transferable to spaceflight hardware. Therefore, while the application of composite design approaches from aircraft and other industries is appealing, many aspects cannot be directly utilized. Nevertheless, experiences and research for composite aircraft structures may be of use in unexpected arenas as space exploration technology develops, and so continued technology exchanges are encouraged.

Raju, Ivatury S.↗

Comparison of Requirements for Composite Structures for Aircraft and Space Applications

In this paper, the aircraft and space vehicle requirements for composite structures are compared. It is a valuable exercise to study composite structural design approaches used in the airframe industry, and to adopt methodology that is applicable for space vehicles. The missions, environments, analysis methods, analysis validation approaches, testing programs, build quantities, inspection, and maintenance procedures used by the airframe industry, in general, are not transferable to spaceflight hardware. Therefore, while the application of composite design approaches from other industries is appealing, many aspects cannot be directly utilized. Nevertheless, experiences and research for composite aircraft structures may be of use in unexpected arenas as space exploration technology develops, and so continued technology exchanges are encouraged.

Raju, Ivatury S.↗

Evaluation of Braided Stiffener Concepts for Transport Aircraft Wing Structure Applications

Braided composite materials have potential for application in aircraft structures. Stiffeners, wing spars, floor beams, and fuselage frames are examples where braided composites could find application if cost effective processing and damage requirements are met. Braiding is an automated process for obtaining near-net shape preforms for fabrication of components for structural applications. Previous test results on braided composite materials obtained at NASA Langley indicate that damage tolerance requirements can be met for some applications. In addition, the braiding industry is taking steps to increase the material through-put to be more competitive with other preform fabrication processes. Data are presented on the compressive behavior of three braided stiffener preform fabric constructions as determined from individual stiffener crippling test and three stiffener wide panel tests. Stiffener and panel fabrication are described and compression data presented for specimens tested with and without impact damage. In addition, data are also presented on the compressive behavior of the stitched stiffener preform construction currently being used by McDonnell Douglas Aerospace in the NASA ACT wing development program.

Deaton, Jerry W.↗

NASGRO 3.0: A Software for Analyzing Aging Aircraft

Structural integrity analysis of aging aircraft is a critical necessity in view of the increasing numbers of such aircraft in general aviation, the airlines and the military. Efforts are in progress by NASA, the FAA and the DoD to focus attention on aging aircraft safety. The present paper describes the NASGRO software which is well-suited for effectively analyzing the behavior of defects that may be found in aging aircraft. The newly revised Version 3.0 has many features specifically implemented to suit the needs of the aircraft community. The fatigue crack growth computer program NASA/FLAGRO 2.0 was originally developed to analyze space hardware such as the Space Shuttle, the International Space Station and the associated payloads. Due to popular demand, the software was enhanced to suit the needs of the aircraft industry. Major improvements in Version 3.0 are the incorporation of the ability to read aircraft spectra of unlimited size, generation of common aircraft fatigue load blocks, and the incorporation of crack-growth models which include load-interaction effects such as retardation due to overloads and acceleration due to underloads. Five new crack-growth models, viz., generalized Willenborg, modified generalized Willenborg, constant closure model, Walker-Chang model and the deKoning-Newman strip-yield model, have been implemented. To facilitate easier input of geometry, material properties and load spectra, a Windows-style graphical user interface has been developed. Features to quickly change the input and rerun the problem as well as examine the output are incorporated. NASGRO has been organized into three modules, the crack-growth module being the primary one. The other two modules are the boundary element module and the material properties module. The boundary-element module provides the ability to model and analyze complex two-dimensional problems to obtain stresses and stress-intensity factors. The material properties module allows users to store and curve-fit fatigue-crack growth data. On-line help and documentation are provided for each of the modules. In addition to the popular PC windows version, a unix-based X-windows version of NASGRO is also available. A portable C++ class library called WxWindows was used to facilitate cross-platform availability of the software.

Mettu, S. R.↗

Pneumatic system structure for circulation control aircraft

A plenum for a circulation control rotor aircraft which surrounds the rotor drive shaft (18) and is so constructed that the top (32), outer (38) and bottom (36) walls through compressed air is admitted are fixed to aircraft structure and the inner wall (34) through which air passes to rotor blades (14) rotates with the drive shaft and rotor blades.

Krauss, Timothy A.↗

Analytical and experimental investigation of aircraft metal structures reinforced with filamentary composites. Phase 2: Structural fatigue, thermal cycling, creep, and residual strength

Specimens representative of metal aircraft structural components reinforced with boron filamentary composites were manufactured and tested under cyclic loading, cyclic temperature, or continuously applied loading to evaluate some of the factors that affect structural integrity under cyclic conditions. Bonded, stepped joints were used throughout to provide composite-to-metal transition regions at load introduction points. Honeycomb panels with titanium or aluminum faces reinforced with unidirectional boron composite were fatigue tested at constant amplitude under completely reversed loading. Results indicated that the matrix material was the most fatigue-sensitive part of the design, with debonding initiating in the stepped joints. However, comparisons with equal weight all-metal specimens show a 10 to 50 times improved fatigue life. Fatigue crack propagation and residual strength were studied for several different stiffened panel concepts, and were found to vary considerably depending on the configuration. Composite-reinforced metal specimens were also subjected to creep and thermal cycling tests. Thermal cycling of stepped joint tensile specimens resulted in a ten percent decrease in residual strength after 4000 cycles.

Blichfeldt, B.↗

Interaction of fluids and structures for aircraft applications

Strong interactions occur between the flow about an aircraft and its structural components, which result in several important aeroelastic phenomena which can significantly influence performance. For example, aircraft with highly swept wings experience vortex-induced aeroelastic oscillations. The simulation of these complex aeroelastic phenomena requires coupling the fluid and structural analysis. This paper provides a summary of the development of such coupled methods and their applications to aeroelasticity. Results based on the transonic small-perturbation equations and the Euler equations are presented.

Guruswamy, Guru P.↗

Technology integration box beam failure study

Composite structures have the potential to be cost effective, structurally efficient primary aircraft structures. As part of the Advanced Composite Technology (ACT) program to exploit this potential for heavily loaded aircraft structures, the design and fabrication of the technology integration box beam (TIBB) was completed. The TIBB is an advanced composite prototype structure for the center wing section of the Lockheed C-130 aircraft. The TIBB was tested for downbending, upbending, torsion, and combined upbending and torsion load conditions to verify the design. The TIBB failed at 83 percent of design ultimate load for the combined upbending and torsion load condition. Current analytical and experimental results are described for a study of the mechanisms that led to the failure of the TIBB. Experimental results include load, strain, and deflection data. An analytical study was conducted of the TIBB structural response. Analytical results include strain and deflection results from a global analysis of the TIBB.

Shuart, Mark J.↗

Structural efficiency study of graphite-epoxy aircraft rib structures

Attention is given to the structural efficiencies obtainable with optimally designed graphite/epoxy wing rib panel configurations that are potentially economically manufacturable. Some ribs are commonly used as fuel cell closeout panels, and are accordingly subjected to out-of-plane pressure loads in addition to the in-plane axial compressive and shear loads resulting from the wing loading. The present minimum-weight panel designs satisfy buckling and strength constraints for wing rib panels subjected to a wide range of combined load conditions.

Swanson, Gary D.↗

Technology integration box beam failure study

Composite structures have the potential to be cost-effective, structurally efficient primary aircraft structures. The Advanced Composites Technology (ACT) Program has the goal to develop the technology to exploit this potential for heavily loaded aircraft structures. As part of the ACT Program, Lockheed Aeronautical Systems Company completed the design and fabrication of the Technology Integration Box Beam (TIBB). The TIBB is an advanced composite prototype structure for the center wing section of the C-130 aircraft. Lockheed subjected the TIBB to downbending, upbending, torsion and combined upbending and torsion load conditions to verify the design. The TIBB failed at 83 percent of design ultimate load for the combined upbending and torsion load condition. The objective of this paper is to describe the mechanisms that led to the failure of the TIBB. The results of a comprehensive analytical and experimental study are presented. Analytical results include strain and deflection results from both a global analysis of the TIBB and a local analysis of the failure region. These analytical results are validated by experimental results from the TIBB tests. The analytical and experimental results from the TIBB tests are used to determine a sequence of events that resulted in failure of the TIBB. A potential cause of failure is high stresses in a stiffener runout region. Analytical and experimental results are also presented for a stiffener runout specimen that was used to simulate the TIBB failure mechanisms.

Shuart, M. J.↗

Analytical and experimental investigation of aircraft metal structures reinforced with filamentary composites. Phase 3: Major component development

Analytical and experimental investigations, performed to establish the feasibility of reinforcing metal aircraft structures with advanced filamentary composites, are reported. Aluminum-boron-epoxy and titanium-boron-epoxy were used in the design and manufacture of three major structural components. The components were representative of subsonic aircraft fuselage and window belt panels and supersonic aircraft compression panels. Both unidirectional and multidirectional reinforcement concepts were employed. Blade penetration, axial compression, and inplane shear tests were conducted. Composite reinforced structural components designed to realistic airframe structural criteria demonstrated the potential for significant weight savings while maintaining strength, stability, and damage containment properties of all metal components designed to meet the same criteria.

Bryson, L. L.↗

Design-Oriented Analysis of Aircraft Fuselage Structures

A design-oriented analysis capability for aircraft fuselage structures that utilizes equivalent plate methodology is described. This new capability is implemented as an addition to the existing wing analysis procedure in the Equivalent Laminated Plate Solution (ELAPS) computer code. The wing and fuselage analyses are combined to model entire airframes. The paper focuses on the fuselage model definition, the associated analytical formulation and the approach used to couple the wing and fuselage analyses. The modeling approach used to minimize the amount of preparation of input data by the user and to facilitate the making of design changes is described. The fuselage analysis is based on ring and shell equations but the procedure is formulated to be analogous to that used for plates in order to take advantage of the existing code in ELAPS. Connector springs are used to couple the wing and fuselage models. Typical fuselage analysis results are presented for two analytical models. Results for a ring-stiffened cylinder model are compared with results from conventional finite-element analyses to assess the accuracy of this new analysis capability. The connection of plate and ring segments is demonstrated using a second model that is representative of the wing structure for a channel-wing aircraft configuration.

Giles, Gary L.↗

Dynamic Structural Fault Detection and Identification

Aircraft structures are designed to guarantee safety of flight in some required operational envelope. When the aircraft becomes structurally impaired, safety of flight may not be guaranteed within that previously safe operational envelope. In this case the safe operational envelope must be redefined in-flight and a means to prevent excursion from this new envelope must be implemented. A specific structural failure mode that may result in a reduced safe operating envelope, the exceedance of which could lead to catastrophic structural failure of the aircraft, will be addressed. The goal of the DFEAP program is the detection of this failure mode coupled with flight controls adaptation to limit critical loads in the damaged aircraft structure. The DFEAP program is working with an F/A-18 aircraft model. The composite wing skins are bonded to metallic spars in the wing substructure. Over time, it is possible that this bonding can deteriorate due to fatigue. In this case, the ability of the wing spar to transfer loading between the wing skins is reduced. This failure mode can translate to a reduced allowable compressive strain on the wing skin and could lead to catastrophic wing buckling if load limiting of the wing structure is not applied. The DFEAP program will make use of a simplified wing strain model for the healthy aircraft. The outputs of this model will be compared in real-time to onboard strain measurements at several locations on the aircraft wing. A damage condition is declared at a given location when the strain measurements differ sufficiently from the strain model. Parameter identification of the damaged structure wing strain parameters will be employed to provide load limiting control adaptation for the aircraft. This paper will discuss the simplified strain models used in the implementation and their interaction with the strain sensor measurements. Also discussed will be the damage detection and identification schemes employed and the means by which the damaged aircraft parameters will be used to provide load limiting that keeps the aircraft within the safe operational envelope.

Smith, Timothy↗

Novel matrix resins for composites for aircraft primary structures, phase 1

The objective of the contract is the development of matrix resins with improved processability and properties for composites for primarily aircraft structures. To this end, several resins/systems were identified for subsonic and supersonic applications. For subsonic aircraft, a series of epoxy resins suitable for RTM and powder prepreg was shown to give composites with about 40 ksi compressive strength after impact (CAI) and 200 F/wet mechanical performance. For supersonic applications, a thermoplastic toughened cyanate prepreg system has demonstrated excellent resistance to heat aging at 360 F for 4000 hours, 40 ksi CAI and useful mechanical properties at greater than or equal to 310 F. An AB-BCB-maleimide resin was identified as a leading candidate for the HSCT. Composite panels fabricated by RTM show CAI of approximately 50 ksi, 350 F/wet performance and excellent retention of mechanical properties after aging at 400 F for 4000 hours.

Woo, Edmund P.↗

Evaluation of bonded boron/epoxy doublers for commercial aircraft aluminum structures

An 18 month laboratory test and stress analysis program was conducted to evaluate bonded boron/epoxy doublers for repairing cracks on aluminum aircraft structures. The objective was to obtain a core body of substantiating data which will support approval for use on commercial transports of a technology that is being widely used by the military. The data showed that the doublers had excellent performance.

Belason, Bruce↗

Analytical and experimental investigation of aircraft metal structures reinforced with filamentary composites. Phase 1: Concept development and feasibility

The analytical and experimental investigations are described in the first phase of a program to establish the feasibility of reinforcing metal aircraft structures with advanced filamentary composites. The interactions resulting from combining the two types of materials into single assemblies as well as their ability to function structurally were studied. The combinations studied were boron-epoxy reinforced aluminum, boron-epoxy reinforced titanium, and boron-polyimide reinforced titanium. The concepts used unidirectional composites as reinforcement in the primary loading direction and metal for carrying the transverse loads as well as its portion of the primary load. The program established that several realistic concepts could be fabricated, that these concepts could perform to a level that would result in significant weight savings, and that there are means for predicting their capability within a reasonable degree of accuracy. This program also encountered problems related to the application of polyimide systems that resulted in their relatively poor and variable performance.

Oken, S.↗