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NASA NTRS1937

Plastics as structural materials for aircraft

The purpose here is to consider the mechanical characteristics of reinforced phenol-formaldehyde resin as related to its use as structural material for aircraft. Data and graphs that have appeared in the literature are reproduced to illustrate the comparative behavior of plastics and materials commonly used in aircraft construction. Materials are characterized as to density, static strength, modulus of elasticity, resistance to long-time loading, strength under repeated impact, energy absorption, corrosion resistance, and ease of fabrication.

Kline, G M↗

NASA NTRS1994

An optical technique for examining aircraft shock wave structures in flight

The detailed properties of sonic booms have to be better understood before commercial, next generation, supersonic and hypersonic aircraft can be properly developed. Experimental tests and measurements are needed to help sort the physical details of the flows at realistic test conditions. Some of these tests can be made in wind tunnels, but the need for full flight conditions simulation, the problem of tunnel wall interference, and the short distance the shocks can be examined from the aircraft, limit the usefulness of wind tunnel tests. Previous measurement techniques for examining the flow field of aircraft in flight have included pressure measurements on the aircraft, ground based pressure measurements, and flow field measurements made with chase aircraft. Obtaining data with chase planes is a slow and difficult process, and is limited in how close it can be obtained to the test aircraft. A need clearly existed for a better technique to examine the shock structure from the plane to large distances from the plane. A new technique has been recently developed to obtain schlieren photographs of aircraft in flight (SAF). Preliminary results have been obtained, and the technique holds promise as a tool to study the shape and approximate strength of the shock wave structure around the test aircraft, and examine shock wave details all the way from the aircraft to near the ground. The current paper describes this approach, and gives some preliminary test results.

Weinstein, Leonard M.↗

NASA NTRS1990

Design, analysis, and testing of a reusable wingbox for ballistic evaluation of composite structures

Future fighter aircraft will continue to be subjected to severe mechanical loading and ballistic impact. In the past aircraft primary wing structure was constructed predominantly with aluminum, but with increasing aircraft performance the need for more structurally efficient materials is necessary. In an attempt to achieve structural efficiency requirements, aircraft designers have begun using an increasing amount of composite materials. Composite materials were indicated to have a low level of ballistic tolerance in some applications. Composite materials possess the characteristic of structural tailoring, which was utilized to demonstrate that survivability can be designed into a structure. The combat flight environment subjects fighter aircraft wing structures to the effects of combined loading during ballistic impact. These loads were previously demonstrated independently, i.e., the application of structural load, hydrodynamic ram damage, and the effects of airflow. The objective was to design a reusable test fixture for the ballistic evaluation of advanced composite structures under all the effects of combined loading. The fixture that was developed provides a test bed that can completely simulate the flight environment of a generic fighter aircraft wing, but can be used for an indefinite number and variety of tests. It is intended that this fixture will provide a standardized method of ballistically evaluating an advanced composite primary wing structure. This fixture will be used to accomplish the development of designs and/or advanced concepts that lead to a survivable composite wing structure.

Baron, W. G.↗

NASA NTRS1979

Actively cooled plate fin sandwich structural panels for hypersonic aircraft

An unshielded actively cooled structural panel was designed for application to a hypersonic aircraft. The design was an all aluminum stringer-stiffened platefin sandwich structure which used a 60/40 mixture of ethylene glycol/water as the coolant. Eight small test specimens of the basic platefin sandwich concept and three fatigue specimens from critical areas of the panel design was fabricated and tested (at room temperature). A test panel representative of all features of the panel design was fabricated and tested to determine the combined thermal/mechanical performance and structural integrity of the system. The overall findings are that; (1) the stringer-stiffened platefin sandwich actively cooling concept results in a low mass design that is an excellent contender for application to a hypersonic vehicle, and (2) the fabrication processes are state of the art but new or modified facilities are required to support full scale panel fabrication.

Smith, L. M.↗

NASA NTRS2015

Active Structural Control for Aircraft Efficiency with the X-56A Aircraft

The X-56A Multi-Utility Technology Testbed is an experimental aircraft designed to study active control of flexible structures. The vehicle is easily reconfigured to allow for testing of different configurations. The vehicle is being used to study new sensor, actuator, modeling and controls technologies. These new technologies will allow for lighter vehicles and new configurations that exceed the efficiency currently achievable. A description of the vehicle and the current research efforts that it enables are presented.

aeroservoelasticity↗

NASA NTRS1976

A new role for structures technology in aircraft configuration development

It is pointed out that decisions made during configuration development determine nearly 60% of the total program cost. The key to the new Structures Technology role considered is the development of integrated computer systems for structural design and analysis. Such systems make it possible to include structural sizing within the scope of preliminary configuration development. Analysis models are discussed, taking into account approaches used to determine the structural weight of an aircraft in the preliminary design stage, a finite element representation for a supersonic arrow wing transport, and the aerodynamic model. Attention is given to automated design considerations and a study which was conducted to reduce the aerodynamic drag of a supersonic transport by blending the structure of the wing and fuselage.

Nisbet, J. W.↗

NASA NTRS2015

Development of Stitched Composite Structure for Advanced Aircraft

NASA has created the Environmentally Responsible Aviation Project to develop technologies which will reduce the impact of aviation on the environment. A critical aspect of this pursuit is the development of a lighter, more robust airframe that will enable the introduction of unconventional aircraft configurations. NASA and The Boeing Company are working together to develop a structural concept that is lightweight and an advancement beyond state-of-the-art composites. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is an integrally stiffened panel design where elements are stitched together and designed to maintain residual load-carrying capabilities under a variety of damage scenarios. With the PRSEUS concept, through-the-thickness stitches are applied through dry fabric prior to resin infusion, and replace fasteners throughout each integral panel. Through-the-thickness reinforcement at discontinuities, such as along flange edges, has been shown to suppress delamination and turn cracks, which expands the design space and leads to lighter designs. The pultruded rod provides stiffening away from the more vulnerable skin surface and improves bending stiffness. A series of building blocks were evaluated to explore the fundamental assumptions related to the capability and advantages of PRSEUS panels. These building blocks addressed tension, compression, and pressure loading conditions. The emphasis of the development work has been to assess the loading capability, damage arrestment features, repairability, post-buckling behavior, and response of PRSEUS flat panels to out-of plane pressure loading. The results of this building-block program from coupons through an 80%-scale pressure box have demonstrated the viability of a PRSEUS center body for the Hybrid Wing Body (HWB) transport aircraft. This development program shows that the PRSEUS benefits are also applicable to traditional tube-andwing aircraft, those of advanced configurations, and other structures where weight and through-the-thickness strength are design considerations. An overview of the development of PRSEUS technology for commercial transport aircraft is the subject of this paper.

Jegley, Dawn↗

NASA NTRS1975

Simultaneous calculation of aircraft design loads and structural member sizes

A design process which accounts for the interaction between aerodynamic loads and changes in member sizes during sizing of aircraft structures is described. A simultaneous iteration procedure is used wherein both design loads and member sizes are updated during each cycle yielding converged, compatible loads and member sizes. A description is also given of a system of programs which incorporates this process using lifting surface theory to calculate aerodynamic pressure distributions, using a finite-element method for structural analysis, and using a fully stressed design technique to size structural members. This system is tailored to perform the entire process with computational efficiency in a single computer run so that it can be used effectively during preliminary design. Selected results, considering maneuver, taxi, and fatigue design conditions, are presented to illustrate convergence characteristics of this iterative procedure.

Giles, G. L.↗

NASA NTRS1992

Composite fuselage shell structures research at NASA Langley Research Center

Fuselage structures for transport aircraft represent a significant percentage of both the weight and the cost of these aircraft primary structures. Composite materials offer the potential for reducing both the weight and the cost of transport fuselage structures, but only limited studies of the response and failure of composite fuselage structures have been conducted for transport aircraft. The behavior of these important primary structures must be understood, and the structural mechanics methodology for analyzing and designing these complex stiffened shell structures must be validated in the laboratory. The effects of local gradients and discontinuities on fuselage shell behavior and the effects of local damage on pressure containment must be thoroughly understood before composite fuselage structures can be used for commercial aircraft. This paper describes the research being conducted and planned at NASA LaRC to help understand the critical behavior or composite fuselage structures and to validate the structural mechanics methodology being developed for stiffened composite fuselage shell structure subjected to combined internal pressure and mechanical loads. Stiffened shell and curved stiffened panel designs are currently being developed and analyzed, and these designs will be fabricated and then tested at Langley to study critical fuselage shell behavior and to validate structural analysis and design methodology. The research includes studies of the effects of combined internal pressure and mechanical loads on nonlinear stiffened panel and shell behavior, the effects of cutouts and other gradient-producing discontinuities on composite shell response, and the effects of local damage on pressure containment and residual strength. Scaling laws are being developed that relate full-scale and subscale behavior of composite fuselage shells. Failure mechanisms are being identified and advanced designs will be developed based on what is learned from early results from the LaRC research activities. Results from combined load tests will be used to validate analytical models of critical nonlinear response mechanisms as well as shell scaling laws.

Starnes, James H., Jr.↗

NASA NTRS2014

Elastomeric Structural Attachment Concepts for Aircraft Flap Noise Reduction - Challenges and Approaches to Hyperelastic Structural Modeling and Analysis

Airframe noise is a significant part of the overall noise of transport aircraft during the approach and landing phases of flight. Airframe noise reduction is currently emphasized under the Environmentally Responsible Aviation (ERA) and Fixed Wing (FW) Project goals of NASA. A promising concept for trailing-edge-flap noise reduction is a flexible structural element or link that connects the side edges of the deployable flap to the adjacent main-wing structure. The proposed solution is distinguished by minimization of the span-wise extent of the structural link, thereby minimizing the aerodynamic load on the link structure at the expense of increased deformation requirement. Development of such a flexible structural link necessitated application of hyperelastic materials, atypical structural configurations and novel interface hardware. The resulting highly-deformable structural concept was termed the FLEXible Side Edge Link (FLEXSEL) concept. Prediction of atypical elastomeric deformation responses from detailed structural analysis was essential for evaluating feasible concepts that met the design constraints. The focus of this paper is to describe the many challenges encountered with hyperelastic finite element modeling and the nonlinear structural analysis of evolving FLEXSEL concepts. Detailed herein is the nonlinear analysis of FLEXSEL concepts that emerged during the project which include solid-section, foamcore, hollow, extended-span and pre-stressed concepts. Coupon-level analysis performed on elastomeric interface joints, which form a part of the FLEXSEL topology development, are also presented.

Sreekantamurthy, Thammaiah↗

NASA NTRS1955

NACA Conference on Aircraft Loads, Flutter, and Structures - A compilation of the papers presented

Conference on aircraft loads, flutter, buffeting, and structures

LOADING↗

NASA NTRS1992

Advanced tow placement of composite fuselage structure

The Hercules NASA ACT program was established to demonstrate and validate the low cost potential of the automated tow placement process for fabrication of aircraft primary structures. The program is currently being conducted as a cooperative program in collaboration with the Boeing ATCAS Program. The Hercules advanced tow placement process has been in development since 1982 and was developed specifically for composite aircraft structures. The second generation machine, now in operation at Hercules, is a production-ready machine that uses a low cost prepreg tow material form to produce structures with laminate properties equivalent to prepreg tape layup. Current program activities are focused on demonstration of the automated tow placement process for fabrication of subsonic transport aircraft fuselage crown quadrants. We are working with Boeing Commercial Aircraft and Douglas Aircraft during this phase of the program. The Douglas demonstration panels has co-cured skin/stringers, and the Boeing demonstration panel is an intricately bonded part with co-cured skin/stringers and co-bonded frames. Other aircraft structures that were evaluated for the automated tow placement process include engine nacelle components, fuselage pressure bulkheads, and fuselage tail cones. Because of the cylindrical shape of these structures, multiple parts can be fabricated on one two placement tool, thus reducing the cost per pound of the finished part.

Anderson, Robert L.↗

NASA NTRS2012

TPSAS-NF1676L-13678-DND

An area that shows promise in enhancing structural integrity of aircraft and aerospace structures is integral stitched composite technology. The most recent generation of this technology is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. The goal of the PRSEUS concept is to provide damage-containment capability for composite structures while reducing overall structural weight. The National Aeronautics and Space Administration, the Boeing Company, and the Federal Aviation Administration (FAA) have partnered in an effort to assess the damage-containment features of a full-scale curved PRSEUS panel using the FAA Full-Scale Aircraft Structural Test Evaluation and Research facility. The background, test plan, fixture modifications, pre-test analysis, and planned experimental procedure were presented at the 2011 Aircraft Airworthiness and Sustainment Conference. This follow-on paper and presentation will provide details of the experimental procedure, test results, nondestructive inspection results, and preliminary test analysis comparison. The test program included three phases of loading and inspections: Phase I, as-built; Phase II, with barely visible impact damage (BVID); and Phase III, with a two-bay notch severing the central stiffener. Axial tension, internal pressure, and combined axial tension and internal pressure load conditions were applied during each phase using load levels that demonstrate compliance with the strength, deformation, and damage-tolerance requirements of Title 14 Code of Federal Regulations Part 25. Pressure loads were based on an operating pressure of 9.2 psi, designated as 1P, and the axial loads were based on a design limit load (DLL) of 227 kip. The Phase I test results provided a baseline. First, 50 percent limit-load levels were applied for each of the three load cases to verify proper load introduction and repeatability by examining strain and displacement results. Next, three limit-load cases were applied: limit pressure of 12.2 psi (1.33 P), axial DLL of 227 kip, and combined 1P pressure and axial DLL. Linear strain and displacement results were observed in all load cases. For Phase-II testing, the panel was impacted to introduce BVID with an energy of 40 ft-lb, with the impact located between the central stringer stitch line and flange edge. The impact created non-penetrating visual damage with fiber breaks and delamination between the skin and stringer flange. Limit-load conditions were applied followed by pressure overload of 18.4 psi (2P) and ultimate load conditions, defined as 1.5 times DLL. Inspections were performed after each load case; no damage growth was observed. For Phase-III testing, a two-bay notch was machined severing the central stiffener. The panel was then subjected to limit-load conditions, followed by combined 1P pressure while increasing axial tension load to catastrophic failure. As limit combined loads were approached, damage initiation was observed in the form of 45? splitting at 1P + 79% DLL. Axial loading was increased to 1P + 150 percent DLL causing damage to propagate to the adjacent stringer flanges. Damage was contained within the two-bay region by the stitching rows up to 1P + 176% DLL. Axial load was further increased until catastrophic failure, when a stringer rod failed at 1P + 192% DLL. These test results further verify the damage containment features of the PRSEUS concept and suggest its appropriateness for future flight vehicles.

Andrew Bergan↗

NASA NTRS2012

Full-Scale Test and Analysis Results of a PRSEUS Fuselage Panel to Assess Damage Containment Features

Integrally stitched composite technology is an area that shows promise in enhancing the structural integrity of aircraft and aerospace structures. The most recent generation of this technology is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. The goal of the PRSEUS concept relevant to this test is to provide damage containment capability for composite structures while reducing overall structural weight. The National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), and The Boeing Company have partnered in an effort to assess the damage containment features of a full-scale curved PRSEUS panel using the FAA Full-Scale Aircraft Structural Test Evaluation and Research (FASTER) facility. A single PRSEUS test panel was subjected to axial tension, internal pressure, and combined axial tension and internal pressure loads. The test results showed excellent performance of the PRSEUS concept. No growth of Barely Visible Impact Damage (BVID) was observed after ultimate loads were applied. With a two-bay notch severing the central stringer, damage was contained within the two-bay region well above the required limit load conditions. Catastrophic failure was well above the ultimate load level. Information describing the test panel and procedure has been previously presented, so this paper focuses on the experimental procedure, test results, nondestructive inspection results, and preliminary test and analysis correlation.

Bergan, Andrew↗

NASA NTRS1924

Structural Weight of Aircraft as Affected by the System of Design

Various details of design or arrangement of the parts of airplane structures are shown and discussed, the use of these devices having resulted in the production of structures of adequate strength, yet of a weight less than one-half of the usual construction.

AIRPLANES - DESIGN↗

NASA NTRS2000

Robust Fault Detection for Aircraft Using Mixed Structured Singular Value Theory and Fuzzy Logic

The purpose of fault detection is to identify when a fault or failure has occurred in a system such as an aircraft or expendable launch vehicle. The faults may occur in sensors, actuators, structural components, etc. One of the primary approaches to model-based fault detection relies on analytical redundancy. That is the output of a computer-based model (actually a state estimator) is compared with the sensor measurements of the actual system to determine when a fault has occurred. Unfortunately, the state estimator is based on an idealized mathematical description of the underlying plant that is never totally accurate. As a result of these modeling errors, false alarms can occur. This research uses mixed structured singular value theory, a relatively recent and powerful robustness analysis tool, to develop robust estimators and demonstrates the use of these estimators in fault detection. To allow qualitative human experience to be effectively incorporated into the detection process fuzzy logic is used to predict the seriousness of the fault that has occurred.

Collins, Emmanuel G.↗

NASA NTRS2009

Experimental Behavior of Fatigued Single Stiffener PRSEUS Specimens

NASA, the Air Force Research Laboratory and The Boeing Company have worked to develop new low-cost, light-weight composite structures for aircraft. A Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept has been developed which offers advantages over traditional metallic structure. In this concept a stitched carbon-epoxy material system has been developed with the potential for reducing the weight and cost of transport aircraft structure by eliminating fasteners, thereby reducing part count and labor. By adding unidirectional carbon rods to the top of stiffeners, the panel becomes more structurally efficient. This combination produces a more damage tolerant design. This document describes the results of experimentation on PRSEUS specimens loaded in unidirectional compression in fatigue and to failure.

Jegley, Dawn C.↗

NASA NTRS2010

Influence of Impact Damage on Carbon-Epoxy Stiffener Crippling

Jegley, Dawn C.↗