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The effort was in two areas: (1) development of advanced methods of flight path optimization, and (2) development of advanced methods of structural weight estimation.
The needs for computerized structural mechanics (CSM) as seen from the standpoint of the aircraft industry are discussed. These needs are projected into the 1990's with special focus on the new advanced materials. Preliminary design/analysis, research, and detail design/analysis are identified as major areas. The role of local/global analyses in these different areas is discussed. The lessons learned in the past are used as a basis for the design of a CSM framework that could modify and consolidate existing technology and include future developments in a rational and useful way. A philosophy is stated, and a set of analyses needs driven by the emerging advanced composites is enumerated. The roles of NASA, the universities, and the industry are identified. Finally, a set of rational research targets is recommended based on both the new types of computers and the increased complexity the industry faces. Computerized structural mechanics should be more than new methods in structural mechanics and numerical analyses. It should be a set of engineering applications software products that combines innovations in structural mechanics, numerical analysis, data processing, search and display features, and recent hardware advances and is organized in a framework that directly supports the design process.
Performance criteria and test techniques are applied to stability augmentation systems (SAS) during ground testing to predict objectionable limit cycles and preclude structural resonance during flight. Factors that give rise to these problems, means of suppressing their effects, trade-offs to be considered, and ground test methods that have been developed are discussed. SAS performance predicted on the basis of these tests is compared with flight data obtained from three lifting body vehicles and the X-15 research airplane. Limit cycle and structural resonance test criteria, based upon ground and flight experience and data, were successfully applied to these vehicles. The criteria used were: The limit cycle amplitude (SAS gain multiplied by peak-to-peak angular rate) shall not exceed 0.5 deg for the highest product of control power and SAS gain that will be used in flight; the maximum in-flight SAS gain should never exceed 50 percent of the value at which a structural resonance can be sustained during ground test.
The results of a program to design and fabricate an unshielded actively cooled structural panel for a hypersonic aircraft are presented. The design is an all-aluminum honeycomb sandwich with embedded cooling passages soldered to the inside of the outer moldline skin. The overall finding is that an actively cooled structure appears feasible for application on a hypersonic aircraft, but the fabrication process is complex and some material and manufacturing technology developments are required. Results from the program are summarized and supporting details are presented.
The impact damage resistance of laminated composite transport aircraft fuselage structures was studied experimentally. A statistically based designed experiment was used to examine numerous material, laminate, structural, and extrinsic (e.g., impactor type) variables. The relative importance and quantitative measure of the effect of each variable and variable interactions on responses including impactor dynamic response, visibility, and internal damage state were determined. The study utilized 32 three-stiffener panels, each with a unique combination of material type, material forms, and structural geometry. Two manufacturing techniques, tow placement and tape lamination, were used to build panels representative of potential fuselage crown, keel, and lower side-panel designs. Various combinations of impactor variables representing various foreign-object-impact threats to the aircraft were examined. Impacts performed at different structural locations within each panel (e.g., skin midbay, stiffener attaching flange, etc.) were considered separate parallel experiments. The relationship between input variables, measured damage states, and structural response to this damage are presented including recommendations for materials and impact test methods for fuselage structure.
A process is described for constructing for a composite laminate structure which exhibits a high resistance to heat and flame provides safer interior structures for aircraft and submarine compartments. Composite laminate structures are prepared by the bismaleimide resin preimpregnation of a fiberglass cloth to form a face sheet which is bonded with a bismaleimide hot melt adhesive to a porous core structure selected from the group consisting of polyamide paper and bismaleimide-glass fabric which is filled with carbon microballoons. The carbon microballoons are prepared by pyrolyzing phenolic micro-balloons in the presence of nitrogen. A slurry of the carbon microballoons is prepared to fill the porous core structure. The porous core structure and face sheet are bonded to provide panel structures exhibiting increased mechanical capacities and lower oxygen limit values and smoke density values.
Composite sandwich structures will be used in many future applications in aerospace, marine and offshore industries due to the fact that the strength and stiffness to mass ratios surpass any other structural type. Sandwich structure also offers advantages over traditional stiffened panels such as ease of manufacturing and repair. During the last three decades, sandwich structure has been used extensively for secondary structure in aircraft (fuselage floors, rudders and radome structure). Sandwich structure is also used as primary structure in rotorcraft, the most common example being the trailing edge of rotor blades. As with other types of composite construction, sandwich structure exhibits several types of failure mode such as facesheet wrinkling, core crushing and sandwich buckling. Facesheet/core debonding has also been observed in the marine and aerospace industry. During this failure mode, peel stresses applied to an existing facesheet/core debond or an interface low in toughness, results in the facesheet being peeled from the core material, possibly leading to a significant loss in structural integrity of the sandwich panel. In an incident during a test on a liquid hydrogen fuel tank of the X-33 prototype vehicle, the outer graphite/epoxy facesheet and honeycomb core became debonded from the inner facesheet along significant areas, leading to failure of the tank. As a consequence of the accident; significant efforts were made to characterize the toughness of the facesheet/core bond. Currently, the only standardized method available for assessing the quality of the facesheet/core interface is the climbing drum peel test (ASTM D1781). During this test a sandwich beam is removed from a panel and the lip of one of the facesheets is attached to a drum, as shown in Fig. 1. The drum is then rotated along the sandwich beam, causing the facesheet to peel from the core. This method has two major drawbacks. First, it is not possible to obtain quantitative fracture data from the test and so the results can only be used in a qualitative manner. Second, only sandwich structure with thin facesheets can be tested (to facilitate wrapping of the facesheet around the climbing drum). In recognition of the need for a more quantitative facesheet/core fracture test, several workers have devised experimental techniques for characterizing the toughness of the facesheet/core interface. In all of these cases, the tests are designed to yield a mode I-dominated fracture toughness of the facesheet/core interface in a manner similar to that used to determine mode I fracture toughness of composite laminates. In the current work, a modified double cantilever beam is used to measure the mode I-dominated fracture toughness of the interface in a sandwich consisting of glass/phenolic honeycomb core reinforced with graphite epoxy facesheets. Two specimen configurations were tested as shown in Fig 2. The first configuration consisted of reinforcing the facesheets with aluminum blocks (Fig. 2a). In the second configuration unreinforced specimens were tested (Fig. 2b). Climbing drum peel tests were also conducted to compare the fracture behavior observed between this test and the modified double cantilever beam. This paper outlines the test procedures and data reduction strategies used to compute fracture toughness values from the tests. The effect of specimen reinforcement on fracture toughness of the facesheet/core interface is discussed.
As part of an ongoing study of the spreading rate of lift-generated vortex wakes, the present investigation considers possible reasons as to why segments of lift-generated wakes sometimes depart from the main part of the wake to move rapidly in either an upward or downward direction. It is assumed that deficiencies or enhancements of the lift carry over across the fuselage-shrouded wing are the driving mechanism for departures of wake-segments. The computations presented first indicate that upwardly departing wake segments that were observed and photographed could have been produced by a deficiency in lift carryover across the fuselage-shrouded part of the wing. Computations made of idealized vortex wakes indicate that upward departure of a wake segment requires a centerline reduction in the span loading of 70% or more, whether the engines are at idle or robust thrust. Similarly, it was found that downward departure of wake segments is produced when the lift over the center part of the wing is enhanced. However, it was also found that downward departures do not occur without the presence of robust engine-exhaust streams (i.e., engines must NOT be at idle). In those cases, downward departures of a wake segment occurs when the centerline value of the loading is enhanced by any amount between about 10% to 100%. Observations of condensation trails indicate that downward departure of wake segments is rare. Upward departures of wake segments appears to be more common but still rare. A study to determine the part of the aircraft that causes wake departures has not been carried out. However, even though departures of wake segments rarely occur, some aircraft do regularly shed these wake structures. If aircraft safety is to be assured to a high degree of reliability, and a solution for eliminating them is not implemented, existing guidelines for the avoidance of vortex wakes [1,3] may need to be broadened to include possible increases in wake sizes caused by vertical departures of wake segments. Further study may indicate that it is not possible to modify existing aircraft enough to prevent wake departures. Wake-avoidance guidelines must then be adjusted to provide the desired degree of safety. It appears that steps to avoid upwardly moving wake segments have already been incorporated into the avoidance procedures used for aircraft on approach to runways at the Frankfurt Airport [6,7]. The uncertainty in the prospects for compromises in flight safety caused by rapidly upwardly or downwardly moving wake segments suggest that it be specified that aircraft do not fly above or below each other during operations in the airport vicinity where aircraft are likely to be closely spaced [20].
An area that shows promise in enhancing structural integrity of aircraft and aerospace structures is the integrally stitched composite technology. The most recent generation of this technology is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept developed by Boeing Research and Technology and the National Aeronautics and Space Administration. A joint test program on the assessment of damage containment capabilities of the PRSEUS concept for curved fuselage structures was conducted recently at the Federal Aviation Administration William J. Hughes Technical Center. The panel was subjected to axial tension, internal pressure, and combined axial tension and internal pressure load conditions up to fracture, with a through-the-thickness, two-bay notch severing the central stiffener. For the purpose of future progressive failure analysis development and verification, extensive post failure nondestructive and teardown inspections were conducted. Detailed inspections were performed directly ahead of the notch tip where stable damage progression was observed. These examinations showed: 1) extensive delaminations developed ahead of the notch tip, 2) the extent and location of damage, 3) the typical damage mechanisms observed in composites, and 4) the role of stitching and warp-knitting in the failure mechanisms. The objective of this paper is to provide a summary of results from these posttest inspections.
The unidirectional carbon pultruded rod running through the tops of the stringers is a key design feature of the Pultruded Rod Efficient Unitized Structure (PRSEUS) concept as applied to aircraft fuselage structure. Reported herein are the test methods and results from a test campaign in which the strength of the rod/overwrap interface of various PRSEUS stringer configurations were characterized. The different stringer configurations included different materials and stacking sequences for the stringer overwrap and whether or not an additional layer of adhesive was included between the rod and the overwrap.
Traditional techniques in structural load measurement entail the correlation of a known load with strain-gage output from the individual components of a structure or machine. The use of strain gages has proved successful and is considered the standard approach for load measurement. However, remotely measuring aerodynamic loads using deflection measurement systems to determine aeroelastic deformation as a substitute to strain gages may yield lower testing costs while improving aircraft performance through reduced instrumentation weight. This technique was examined using a reliable strain and structural deformation measurement system. The objective of this study was to explore the utility of a deflection-based load estimation, using the active aeroelastic wing F/A-18 aircraft. Calibration data from ground tests performed on the aircraft were used to derive left wing-root and wing-fold bending-moment and torque load equations based on strain gages, however, for this study, point deflections were used to derive deflection-based load equations. Comparisons between the strain-gage and deflection-based methods are presented. Flight data from the phase-1 active aeroelastic wing flight program were used to validate the deflection-based load estimation method. Flight validation revealed a strong bending-moment correlation and slightly weaker torque correlation. Development of current techniques, and future studies are discussed.
Inspections of the C-130 composite-reinforced center wings were conducted over the flight service monitoring period of more than six years. Twelve inspections were conducted on each of the two C-130H airplanes having composite reinforced center wing boxes. Each inspection consisted of visual and ultrasonic inspection of the selective boron-epoxy reinforced center wings which included the inspection of the boron-epoxy laminates and the boron-epoxy reinforcement/aluminum structure adhesive bondlines. During the flight service monitoring period, the two C-130H aircraft accumulated more than 10,000 flight hours and no defects were detected in the inspections over this period. The successful performance of the C-130H aircraft with composite-reinforced center wings allowed the transfer of the responsibilities of inspecting and maintaining these two aircraft to the U. S. Air Force.
This paper examines the use of 6.5 micron geostationary satellite imagery during the Stratospheric Radiation And Transport (STRAT) field mission, the first pha:ie of which is during May, 1995. The 6.5 micron imagery is being us4!d to define the horizontal structure of areas where the tropopause is particularly low. Regions of high PV on, say, a 350K surface have been shown to coincide roughly with regions of enhanced radiance. These regions of enhanced 6.5 micron radiance coincide with dryness in the 5-10 km region, since the dryness enables radiation from lower (and warmer) levels to penetrate through the atmosphere into space. Such dryness is associated with downward penetrations of dry stratospheric, high potential vorticity air. We explore the extent to which such regions of high radiance are related to stratospheric intrusions into the troposphere as observed by aircraft data.
A method for rapidly evaluating the structural and aerodynamic characteristics of joined-wing aircraft was developed and used to study the fundamental advantages attributed to this concept. The technique involves a rapid turnaround aerodynamic analysis method for computing minimum trimmed drag combined with a simple structural optimization. A variety of joined-wing designs are compared on the basis of trimmed drag, structural weight, and, finally, trimmed drag with fixed structural weight. The range of joined-wing design parameters resulting in best cruise performance is identified. Structural weight savings and net drag reductions are predicted for certain joined-wing configurations compared with conventional cantilever-wing configurations.
A procedure for automating the design of transport aircraft fuselage structures has been developed and implemented in the form of an operational program. The structure is designed in two stages. First, an overall distribution of structural material is obtained by means of optimality criteria to meet strength and displacement constraints. Subsequently, the detailed design of selected rings and panels consisting of skin and stringers is performed by mathematical optimization accounting for a set of realistic design constraints. The practicality and computer efficiency of the procedure is demonstrated on cylindrical and area-ruled large transport fuselages.
Environmental conditions, cyclic loading, and aging contribute to structural wear and degradation, and thus potentially catastrophic events. The challenge of health monitoring technology is to determine incipient changes accurately and efficiently. This project addresses this challenge by developing health monitoring techniques that depend only on sensor measurements. Since actively controlled excitation is not needed, sensor-to-sensor identification (S2SID) provides an in-flight diagnostic tool that exploits ambient excitation to provide advance warning of significant changes. S2SID can subsequently be followed up by ground testing to localize and quantify structural changes. The conceptual foundation of S2SID is the notion of a pseudo-transfer function, where one sensor is viewed as the pseudo-input and another is viewed as the pseudo-output, is approach is less restrictive than transmissibility identification and operational modal analysis since no assumption is made about the locations of the sensors relative to the excitation.
This paper summarizes on-going modal testing activities at the NASA Langley Research Center for two aircraft fuselage structures: a generic "aluminum testbed cylinder" (ATC) and a Beechcraft Starship fuselage (BSF). Subsequent acoustic tests will measure the interior noise field created by exterior mechanical and acoustic sources. These test results will provide validation databases for interior noise prediction codes on realistic aircraft fuselage structures. The ATC is a 12-ft-long, all-aluminum, scale model assembly. The BSF is a 40-ft-long, all-composite, complete aircraft fuselage. To date, two of seven test configurations of the ATC and all three test configurations of the BSF have been completed. The paper briefly describes the various test configurations, testing procedure, and typical results for frequencies up to 250 Hz.
This paper summarizes on-going modal testing activities at the NASA Langley Research Center for two aircraft fuselage structures: a generic "aluminum testbed cylinder" (ATC) and a Beechcraft Starship fuselage (BSF). Subsequent acoustic tests will measure the interior noise field created by exterior mechanical and acoustic sources. These test results will provide validation databases for interior noise prediction codes on realistic aircraft fuselage structures. The ATC is a 12-ft-long, all-aluminum, scale model assembly. The BSF is a 40-ft-long, all-composite, complete aircraft fuselage. To date, two of seven test configurations of the ATC and all three test configurations of the BSF have been completed. The paper briefly describes the various test configurations, testing procedure, and typical results for frequencies up to 250 Hz.