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The development of graphite-epoxy composite structures for use on commercial transport aircraft is considered. Six components, three secondary structures, and three primary structures, are presently under development. The six components are described along with some of the key features of the composite designs and their projected weight savings.
Statistics on gas turbine rotor failures that have occurred in U.S. commercial aviation during 1975 are presented. The compiled data were analyzed to establish: (1) The incidence of rotor failures and the number of contained and uncontained rotor bursts; (2) The distribution of rotor bursts with respect to engine rotor component; i.e., fan, compressor or turbine; (3) The type of rotor fragment (disk, rim or blade) typically generated at burst; (4) The cause of failure; (5) The type of engines involved; and (6) The flight condition at the time of failure.
The effort required by commercial transport manufacturers to accomplish the transition from current construction materials and practices to extensive use of composites in aircraft wings was investigated. The engineering and manufacturing disciplines which normally participate in the design, development, and production of an aircraft were employed to ensure that all of the factors that would enter a decision to commit to production of a composite wing structure were addressed. A conceptual design of an advanced technology reduced energy aircraft provided the framework for identifying and investigating unique design aspects. A plan development effort defined the essential technology needs and formulated approaches for effecting the required wing development. The wing development program plans, resource needs, and recommendations are summarized.
A plan is defined for a composite wing development effort which will assist commercial transport manufacturers in reaching a level of technology readiness where the utilization of composite wing structure is a cost competitive option for a new aircraft production plan. The recommended development effort consists of two programs: a joint government/industry material development program and a wing structure development program. Both programs are described in detail.
Fifty-two airplane noise recordings, made at several locations around Dulles International Airport, were analyzed to compare the low-frequency noise levels of the Concorde supersonic transport with those of other commercial jet airplanes. Comparisons of the relative low-frequency noise levels which were produced at close and distant locations for departures and arrivals were made for three noise measures: the sound pressure level in the 1/3 octave band centered at 20 Hz, the total sound pressure level in the 1/3 octave bands with center frequencies less than or equal to 125 Hz, and the total sound pressure level in the 1/3 octave bands with center frequencies less than or equal to 500 Hz. Although the absolute noise levels for Concorde were found, in general, to be higher than those for the other airplane types, the level of low-frequency noise of the Concorde relative to the perceived noise level (PNL), effective perceived noise level (EPNL), and overall sound pressure level (OASPL) was within the range established by the other airplane types, except for the arrival operations of four-engine, narrow-body airplanes. The measure OASPL was found to be a significantly better predictor of low-frequency noise level than PNL or EPNL.
The Seasat-A program has been initiated as a 'proof-of-concept' mission to evaluate the effectiveness of remotely sensing oceanology and related meteorological phenomena from a satellite platform in space utilizing sensors developed on previous space and aircraft test programs. The sensors include three active microwave sensors; a radar altimeter, a windfield scatterometer, and a synthetic aperture radar. A passive scanning multifrequency microwave radiometer, visual and infrared radiometer are also included. All weather, day-night measurements of sea surface temperature, surface wind speed/direction and sea state and directional wave spectra will be made. Two key programs are planned for data utilization with users during the mission. Foremost is a program with the commercial ocean community to test the utility of Seasat-A data and to begin the transfer of ocean remote sensing technology to the civil sector. A second program is a solicitation of investigations, led by NOAA, to involve the ocean science community in a series of scientific investigations.
The use of composites represents one of six possible approaches which, according to a NASA program initiated in 1975, could be used collectively to reduce the fuel consumption of commercial transport aircraft by up to 50 percent. A description is provided of a NASA-industry program which will lead to a more extensive use of advanced composites. The approach being taken is to develop, for existing aircraft, components which have potential for significant weight savings. The design of each of the considered components is described, taking into account a graphite/epoxy rudder, an inboard aileron, a graphite-epoxy elevator, a vertical tail, a horizontal tail, and a vertical stabilizer. The components are in various stages of development at this time. Preliminary weight estimates show from 25 to 30 percent weight savings from the use of composites.
As part of an effort to develop reliable, cost effective spacecraft thermal control heat pipes, Lewis Research Center of NASA is conducting life tests on 30 commercially-available heat pipes in 10 groups of different design and material combinations. Materials are aluminum and stainless steel, and working fluids are methanol and ammonia. The formation of noncondensible gas is observed for times exceeding 11,000 hours. The heat transport capacities of the pipes are also determined. Considerable gas is found in two groups of methanol pipes; one group shows no gas. One group of ammonia pipes has no observable gas. Another group has much gas. Manufacturers' processing schedules are examined for differences explaining the presence of gas. Heat transport capacity is found to be severely reduced in some pipes containing gas.
Major aerospace companies are talking about space factories manufacturing billions of dollars worth of high technology materials per year. On the other hand, a recent National Academy of Sciences study team saw little prospect for space manufacturing because, in their opinion, most of the disturbing effects of gravity in the processes they considered could be overcome on the ground for much less expenditure. This paper presents a current assessment of the problems and promises of the Materials Processing in Space Program and outlines a strategy for developing the first products of commercial value. These early products are expected to serve as paradigms of what can be accomplished by manufacturing in space and should stimulate industry to develop space manufacturing to whatever degree is economically justifiable.
The author has identified the following significant results. Seven major counties were examined: Escambia, Bay, Gulf, Franklin, Wakulla, Nassau, and Duval. Population and economic activity were reviewed, along with commercial fishing and port facilities. Recommendations for five northwest Florida counties were based on interpretation of aerial photographs, satellite imagery, an aerial survey site visit, and published data. Major needs in Pensacola included docking, ice supply, and net and engine repair services. Costs for additional docks, an ice plant, and gear storage were estimated at $3,658,600. Port users in Panama City identified additional docking and gear storage as primary needs, along with gear repair and a marine railway. Estimated costs for dock and gear storage were $2,860,000. Added docking, gear storage, and ice supply, as well as gear electronics and diesel repair were needed in Port St. Joe. Costs were calculated at $1,231,500. Franklin County has three ports (Apalachicola - $1,107,000 for docks and gear storage, Eastpoint - $420,000 for additional docks, and Carrabella - $2,824,100 for docks, gear storage, and ice plant).
A two-year study conducted to establish a basis for industry decisions on the application of laminar flow control (LFC) to future commercial transports was presented. Areas of investigation included: (1) mission definition and baseline selection; (2) concepts evaluations; and (3) LFC transport configuration selection and component design. The development and evaluation of competing design concepts was conducted in the areas of aerodynamics, structures and materials, and systems. The results of supporting wind tunnel and laboratory testing on a full-scale LFC wing panel, suction surface opening concepts and structural samples were included. A final LFC transport was configured in incorporating the results of concept evaluation studies and potential performance improvements were assessed. Remaining problems together with recommendations for future research are discussed.
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.
The overall wing study objectives are to study and plan the effort by commercial transport aircraft manufacturers to accomplish the transition from current conventional materials and practices to extensive use of advanced composites in wings of aircraft that will enter service in the 1985-1990 time period. Specific wing study objectives are to define the technology and data needed to support an aircraft manufacturer's commitment to utilize composites primary wing structure in future production aircraft and to develop plans for a composite wing technology program which will provide the needed technology and data.
A study was conducted to define the technology and data needed to support the introduction of advanced composite materials in the wing structure of future production aircraft. The study accomplished the following: (1) definition of acceptance factors, (2) identification of technology issues, (3) evaluation of six candidate wing structures, (4) evaluation of five program options, (5) definition of a composite wing technology development plan, (6) identification of full-scale tests, (7) estimation of program costs for the total development plan, (8) forecast of future utilization of composites in commercial transport aircraft and (9) identification of critical technologies for timely program planning.
Two programs involving over 100 commercial aircraft were initiated to provide global high resolution in-situ windfield and temperature data during the FGGE. The concepts developed for these programs could have important implications for both meteorology and aviation in the near term.
Results of a 2-year study are reported which were carried out to extend the development of laminar flow control (LFC) technology and evaluate LFC systems concepts. The overall objective of the LFC program is to provide a sound basis for industry decisions on the application of LFC to future commercial transports. The study was organized into major tasks to support the stated objectives through application of LFC systems concepts to a baseline LFC transport initially generated for the study. Based on competitive evaluation of these concepts, a final selection was made for incorporation into the final design of an LFC transport which also included other advanced technology elements appropriate to the 1990 time period.
The author has identified the following significant results. An ecological model was developed that relates marsh detritus export and shrimp production. It was based on the hypothesis that the shoreline is a controlling factor in the production of shrimp through regulation of detritus export from the marsh. LANDSAT data were used to develop measurement of shoreline length and areas of marsh having more than 5.0 kilometers of shoreline per square kilometer of area for the Louisiana coast, demonstrating the capability of remote sensing to provide important geographic information. These factors were combined with published tidal ranges and salinities to develop a mathematical model that predicted shrimp production for nine geographic units of the Louisiana coast, as indicated by the long term average commercial shrimp yield.
Activities reported include completion of the program design tasks, resolution of a high fiber volume problem and resumption of specimen fabrication, fixture fabrication, and progress on the analysis methodology and definition of the typical aircraft environment. Program design activities including test specimens, specimen holding fixtures, flap-track fairing tailcones, and ground exposure racks were completed. The problem experienced in obtaining acceptable fiber volume fraction results on two of the selected graphite epoxy material systems was resolved with an alteration to the bagging procedure called out in BAC 5562. The revised bagging procedure, involving lower numbers of bleeder plies, produces acceptable results. All required laminates for the contract have now been laid up and cured. Progress in the area of analysis methodology has been centered about definition of the environment that a commercial transport aircraft undergoes. The selected methodology is analagous to fatigue life assessment.