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Aircraft are being used in service significantly longer than their original design life. This cost driven measure, is subjecting aircraft structures to conditions that are increasing the probability of failure, particularly as a result of aging.
Three aluminum-lithium alloys are provided for high performance aircraft structures and engines. All three alloys contain 3 wt % copper, 2 wt % lithium, 1 wt % magnesium, and 0.2 wt % zirconium. Alloy 1 has no further alloying elements. Alloy 2 has the addition of 1 wt % iron and 1 wt % nickel. Alloy 3 has the addition of 1.6 wt % chromium to the shared alloy composition of the three alloys. The balance of the three alloys, except for incidentql impurities, is aluminum. These alloys have low densities and improved strengths at temperatures up to 260.degree. C. for long periods of time.
Control law system for the collective axis, as well as pitch and roll axes, of an X-Wing aircraft and for the pneumatic valving controlling circulation control blowing for the rotor. As to the collective axis, the system gives the pilot single-lever direct lift control and insures that maximum cyclic blowing control power is available in transition. Angle-of-attach de-coupling is provided in rotary wing flight, and mechanical collective is used to augment pneumatic roll control when appropriate. Automatic gain variations with airspeed and rotor speed are provided, so a unitary set of control laws works in all three X-Wing flight modes. As to pitch and roll axes, the system produces essentially the same aircraft response regardless of flight mode or condition. Undesirable cross-couplings are compensated for in a manner unnoticeable to the pilot without requiring pilot action, as flight mode or condition is changed. A hub moment feedback scheme is implemented, utilizing a P+I controller, significantly improving bandwidth. Limits protect aircraft structure from inadvertent damage. As to pneumatic valving, the system automatically provides the pressure required at each valve azimuth location, as dictated by collective, cyclic and higher harmonic blowing commands. Variations in the required control phase angle are automatically introduced, and variations in plenum pressure are compensated for. The required switching for leading, trailing and dual edge blowing is automated, using a simple table look-up procedure. Non-linearities due to valve characteristics of circulation control lift are linearized by map look-ups.
The NASA AirSTAR system has been designed to address the challenges associated with safe and efficient subscale flight testing of research control laws in adverse flight conditions. In this paper, software elements of this system are described, with an emphasis on components which allow for rapid prototyping and deployment of aircraft control laws. Through model-based design and automatic coding a common code-base is used for desktop analysis, piloted simulation and real-time flight control. The flight control system provides the ability to rapidly integrate and test multiple research control laws and to emulate component or sensor failures. Integrated integrity monitoring systems provide aircraft structural load protection, isolate the system from control algorithm failures, and monitor the health of telemetry streams. Finally, issues associated with software configuration management and code modularity are briefly discussed.
The proof of concept for using surface acoustic wave (SAW) strain sensors in the detection of aircraft fastener failures is demonstrated. SAW sensors were investigated because they have the potential for the development of passive wireless systems. The SAW devices employed four orthogonal frequency coding (OFC) spread spectrum reflectors in two banks on a high temperature piezoelectric substrate. Three SAW devices were attached to a cantilever panel with removable side stiffeners. Damage in the form of fastener failure was simulated by removal of bolts from the side stiffeners. During testing, three different force conditions were used to simulate static aircraft structural response under loads. The design of the sensor, the panel arrangement and the panel testing results are reported. The results show that the sensors successfully detected single fastener failure at distances up to 54.6 cm from the failure site under loaded conditions.
A surrogate model methodology is described for predicting, during flight, the residual strength of aircraft structures that sustain discrete-source damage. Starting with design of experiment, an artificial neural network is developed that takes as input discrete-source damage parameters and outputs a prediction of the structural residual strength. Target residual strength values used to train the artificial neural network are derived from 3D finite element-based fracture simulations. Two ductile fracture simulations are presented to show that crack growth and residual strength are determined more accurately in discrete-source damage cases by using an elastic-plastic fracture framework rather than a linear-elastic fracture mechanics-based method. Improving accuracy of the residual strength training data does, in turn, improve accuracy of the surrogate model. When combined, the surrogate model methodology and high fidelity fracture simulation framework provide useful tools for adaptive flight technology.
New flow effector technology for separation control and enhanced mixing is based upon shape memory alloy hybrid composite (SMAHC) technology. The technology allows for variable shape control of aircraft structures through actively deformable surfaces. The flow effectors are made by embedding shape memory alloy actuator material in a composite structure. When thermally actuated, the flow effector def1ects into or out of the flow in a prescribed manner to enhance mixing or induce separation for a variety of applications, including aeroacoustic noise reduction, drag reduction, and f1ight control. The active flow effectors were developed for noise reduction as an alternative to fixed-configuration effectors, such as static chevrons, that cannot be optimized for airframe installation effects or variable operating conditions and cannot be retracted for off-design or fail-safe conditions. Benefits include: Increased vehicle control, overall efficiency, and reduced noise throughout all f1ight regimes, Reduced flow noise, Reduced drag, Simplicity of design and fabrication, Simplicity of control through direct current stimulation, autonomous re sponse to environmental heating, fast re sponse, and a high degree of geometric stability. The concept involves embedding prestrained SMA actuators on one side of the chevron neutral axis in order to generate a thermal moment and def1ect the structure out of plane when heated. The force developed in the host structure during def1ection and the aerodynamic load is used for returning the structure to the retracted position. The chevron design is highly scalable and versatile, and easily affords active and/or autonomous (environmental) control. The technology offers wide-ranging market applications, including aerospace, automotive, and any application that requires flow separation or noise control.
The elastic stress intensity factor (SIF, commonly denoted as K) is the foundation of practical fracture mechanics (FM) analysis for aircraft structures. This single parameter describes the first-order effects of stress magnitude and distribution as well as the geometry of both structure/component and crack. Hence, the calculation of K is often the most significant step in fatigue analysis based on FM. This presentation will provide several reflections on the current state-of-the-art in SIF solution methods used for practical aerospace applications, including a brief historical perspective, descriptions of some recent and ongoing advances, and comments on some remaining challenges. Newman and Raju made significant early contributions to practical structural analysis by developing closed-form SIF equations for surface and corner cracks in simplified geometries, often based on empirical fits of finite element (FE) solutions. Those solutions (and others like them) were sometimes revised as new analyses were conducted or limitations discovered. The foundational solutions have exhibited striking longevity, despite the relatively "coarse" FE models employed many decades ago. However, in recent years, the accumulation of different generations of solutions for the same nominal geometry has led to some confusion (which solution is correct?), and steady increases in computational capabilities have facilitated the discovery of inaccuracies in some (not all!) of the legacy solutions. Some examples of problems and solutions are presented and discussed, including the challenge of maintaining consistency with legacy design applications. As computational power has increased, the prospect of calculating large numbers of SIF solutions for specific complex geometries with advanced numerical methods has grown more attractive. Fawaz and Andersson, for example, have been generating literally millions of new SIF solutions for different combinations of multiple cracks under simplified loading schemes using p-version FE methods. These data are invaluable, but questions remain about their practical use, because the tabular databases of key results needed to support practical life analysis can occupy gigabytes of storage for only a few classes of geometries. The prospect of using such advanced numerical methods to calculate in real time only those K solutions actually needed to support a specific crack growth analysis is also tempting, but the stark reality is that the computational cost is still so high that the approach is not practical except for specific, critical application problems. Some thoughts are offered about alternative paradigms. Compounding approaches are some of the earliest building blocks of SIF development for more complex geometries. These approaches are especially attractive because of their very low computational cost and their conceptual robustness; they are, in some ways, an intriguing contrast and complement to the brute-force numerical methods. In recent years, researchers at NRC-Canada have published remarkable results showing how compounding approaches can be used to generate accurate solutions for very difficult problems. Examples are provided of some successes--and some limitations--using this approach. These closed-form, tabulated numerical, and compounding approaches have typically been used for simple remote loading with simple load paths to the crack. However, many significant cracks occur in complex stress gradient fields. This is a job for weight function (WF) methods, where the arbitrary stress distribution on the crack plane in the corresponding uncracked body (typically determined using FE methods) is used to determine K. Several significant recent advances in WF methods and solutions are highlighted here. Fueled by advanced 3D numerical methods, many new solutions have been generated for classic geometries such as surface and corner cracks with wide ranges of geometrical validity. A new WF formulation has also be developed for part-through cracks considering the arbitrary stress gradients in all directions in the crack plane (so-called bivariant solutions). Basic WF methods have recently been combined with analytical expressions for crack plane stresses to develop a large family of accurate SIF solutions for corner, surface, and through cracks at internal or external notches with very wide ranges of shapes, sizes, acuities, and offsets. Finally, WF solutions are much faster than FE or boundary element solutions, but can still be much slower than simple closed-form solutions, especially for bivariant solutions that can require 2D numerical integration. Novel pre-integration and dynamic tabular methods have been developed that substantially increase the speed of these advanced WF solutions. The practical utility of advanced SIF methods, including both WF and direct numerical methods, is greatly enhanced if the FM life analysis can be directly and efficiently linked with digital models of the actual structure or component (e.g., FE models for stress analysis). Two recent advances of this type will be described. One approach directly interfaces the FM life analysis with the FE model of the uncracked component (including stress results). Through a powerful graphical user interface, simplified FM life models can be constructed (and visualized) directly on the component model, with the computer collecting the geometry and stress gradient information needed for the life calculation. An even more powerful paradigm uses expert logic to automatically build an optimum simple fracture model at any and every desired location in the component model, perform the life calculation, and even generate fatigue crack growth life contour maps, all with minimal user intervention. This paradigm has also been extended to the automatic calculation of fracture risk, considering uncertainty or variability in key input parameters such as initial crack size or location. Another new integrated approach links the engineering life analysis, the component model, and a 3D numerical fracture analysis built with the same component model to generate a table of SIF values at a specific location that can then be employed efficiently to perform the life calculation. Some attention must be given to verification and validation (V&V) issues and challenges: how good are these SIF solutions, how good is good enough, and does anyone believe the life answer? It is important to think critically about the different sources of error or uncertainty and to perform V&V in a hierarchal, building-block manner. Some accuracy issues for SIF solutions, for example, may actually involve independent material behavior issues, such as constraint loss effects for crack fronts near component surfaces, and can be a source of confusion. Recommendations are proposed for improved V&V approaches. This presentation will briefly but critically survey the range of issues and advances mentioned above, with a particular view towards assembling an integrated approach that combines different methods to create practical tools for real-world design and analysis problems. Examples will be selectively drawn from the recent literature, from recent enhancements in the NASGRO and DARWIN computer codes, and from previously unpublished research
NASA and the Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A stitched carbon-epoxy material system was developed to reduce the weight and cost of transport aircraft wing structure, first in the NASA Advanced Composites Technology (ACT) program in the 1990's and now in the Environmentally Responsible Aviation (ERA) Project. By stitching through the thickness of a dry carbon fiber material prior to cure, the labor associated with panel fabrication and assembly can be significantly reduced and the need for mechanical fasteners is almost eliminated. Stitching provides the benefit of reducing or eliminating delaminations, including those between stiffener flanges and skin. Stitching also reduces part count, and therefore, cost of the structure. The stitched panel concept used in the ACT program in the 1990's used simple blade-stiffeners as stringers, caps and clips. Today, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is being developed for application to advanced vehicle configurations. PRSEUS provides additional weight savings through the use of a stiffener with a thin web and a unidirectional carbon rod at the top of the web which provides structurally efficient stiffening. A comparison between the blade-stiffened structure and PRSEUS is presented focusing on highly loaded structure and demonstrating improved weight reduction.
Currently, design of aircraft structures incorporate a safety factor which is essentially an over design to mitigate the risk of structure failure during operation. Typically this safety factor is to design the structure to withstand loads much greater than what is expected to be experienced during flight. NASA Dryden Flight Research Centers has developed a Fiber Optic Strain Sensing (FOSS) system which can measure strain values in real-time. The Aeroelastics Lab at the AERO Institute is developing a segmented trailing edged wing with multiple control surfaces that can utilize the data from the FOSS system, in conjunction with an adaptive controller to redistribute the lift across a wing. This redistribution can decrease the amount of strain experienced by the wing as well as be used to dampen vibration and reduce flutter.
The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.
With growing trend toward higher temperature capabilities, lightweight, and multifunctionality, significant advances in ceramic matrix composites (CMCs) will be required for future aerospace applications. The presentation will provide an overview of material requirements for future aerospace missions, and the role of ceramics and CMCs in meeting those requirements. Aerospace applications will include gas turbine engines, aircraft structure, hypersonic and access to space vehicles, space power and propulsion, and space communication.
Carbon fiber reinforced polymer (CFRP) composites possess many advantages for aircraft structures over conventional aluminum alloys: light weight, higher strength- and stiffness-to-weight ratio, and low life-cycle maintenance costs. However, the relatively low thermal and electrical conductivities of CFRP composites are deficient in providing structural safety under certain operational conditions such as lightning strikes. One possible solution to these issues is to interleave carbon nanotube (CNT) sheets between conventional carbon fiber (CF) composite layers. However, the thermal and electrical properties of the orthotropic hybrid CNT/CF composites have not been fully understood. In this study, hybrid CNT/CF polymer composites were fabricated by interleaving layers of CNT sheets with Hexcel (Registered Trademark) IM7/8852 prepreg. The CNT sheets were infused with a 5% solution of a compatible epoxy resin prior to composite fabrication. Orthotropic thermal and electrical conductivities of the hybrid polymer composites were evaluated. The interleaved CNT sheets improved the in-plane thermal conductivity of the hybrid composite laminates by about 400% and the electrical conductivity by about 3 orders of magnitude.
The feed-forward relationship between diagnosis and prognosis is the foundation of both aircraft structural health management and the digital twin concept. Measurements of structural response are obtained either in-situ with mounted sensor networks or offline using more traditional techniques (e.g., nondestructive evaluation). Diagnosis algorithms process this information to detect and quantify damage and then feed this data forward to a prognostic framework. A prognosis of the structure's future operational readiness (e.g., remaining useful life or residual strength) is then made and is used to inform mission- critical decision-making. Years of research have been devoted to improving the elements of this process, but the process itself has not changed significantly. Here, a new approach is proposed in which prognosis information is not only fed forward for decision-making, but it is also fed back to the forthcoming diagnosis. In this way, diagnosis algorithms can take advantage of a priori information about the expected state of health, rather than operating in an uninformed condition. As a feasibility test, a diagnosis-prognosis feedback loop of this manner is demonstrated. The approach is applied to a numerical example in which fatigue crack growth is simulated in a simple aluminum alloy test specimen. A prognosis was derived from a set of diagnoses which provided feedback to a subsequent set of diagnoses. Improvements in accuracy and a reduction in uncertainty in the prognosis- informed diagnoses were observed when compared with an uninformed diagnostic approach.
The topic of this presentation is the impact of formation flying for improved efficiency on aircraft structures.
Design of robust aircraft structure requires consideration of the load-carrying capability with large damage. Large notches, typically introduced as machined cracks (aka "notches") severing a single skin bay and a central stiffening member, are often used to conservatively address the wide range of possible large damage scenarios. The objective of the current effort was to develop more generalized and rapid analysis methods addressing large-notch residual strength of stiffened panels to support preliminary design activities..
Significant testing is required to design and certify primary aircraft structure subject to High Energy Dynamic Impact (HEDI) events; current work under the NASA Advanced Composites Consortium (ACC) HEDI Project seeks to determine the state-of-the-art of dynamic fracture simulations for composite structures in these events. This paper discusses one of four Progressive Damage Analysis (PDA) methods selected for this project: peridynamics, through EMU implementation. A brief discussion of peridynamic theory is provided, followed by an outline of ballistic impact testing performed for model development and assessment. Detailed modeling approach and test-analysis correlation for a single open test case are presented, followed by the results of a series of blind predictions made prior to testing and test-analysis correlation performed with measured NASA test results. Specifically, we present simulation results for the ballistic limit (V50) of IM7/8552 composite panels ballistically tested with an impactor representative of a high-velocity fan-blade-out condition. In particular, force and displacement history and the damage state determined analytically are compared to measured results. Ultimately, peridynamics has the ability to predict damage patterns, impact force and deflections during a high energy dynamic impact event on composite panels of different layups using two different types of impactors. Blind predictions were promising and increased confidence in the model for impact simulation. There are open questions regarding the fidelity of the test fixture idealization in regards to stiffness and damping which will need to be addressed in future work.
Designs of aircraft structures have been moving toward leaner, lightweight designs for increased fuel efficiency. The Passive Aeroelastic Tailored (PAT) wing developed under the NASA Advanced Air Transport Technology (AATT) project is an example of a swept-wing design with high aspect ratio that incorporates lightweight highly-flexible tailored composite construction. The passive aeroelastic tailored structural design has explored the design space to enable aeroelastically tailored wing structures to increase aspect ratios (from 9 to 14) and ultimately reduce weight by 20 percent to 25 percent without impacting aeroelastic performance. To further study the aeroelastic performance of such a wing, the NASA Armstrong Flight Research Center (AFRC) (Edwards, California) has developed efficient real-time structural algorithms that are used in conjunction with a fiber-optic measurement system for lightweight vehicle applications. The AFRC Fiber Optic Sensing System (FOSS) provides up to 8,000 distributed surface strain measurements at one-half-inch increments and can be used to estimate a variety of structural parameters such as shape and load. This report discusses the implementation of strain-based displacement and twist-sensing techniques applied to the PAT wing test article tested at the NASA AFRC Flight Loads Laboratory. Empirical FOSS strain data are collected under varying loading conditions. Strain data are processed with the displacement and twist-sensing algorithms and independently verified by comparison to conventional ground-based instrumentation.